EPA-340/1-73-001-Q
TECHNICAL GUIDE FOR REVIEW AND
EVALUATION OF COMPLIANCE SCHEDULES
FOR AIR POLLUTION SOURCES
U. S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT AND GENERAL COUNSEL
OFFICE OF GENERAL ENFORCEMENT
DIVISION OF STATIONARY SOURCE ENFORCEMENT
WASHINGTON. D. C. 20460
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EPA-340/l-73-001-a
TECHNICAL GUIDE FOR REVIEW AND
EVALUATION OF COMPLIANCE SCHEDULES
FOR AIR POLLUTION SOURCES
by
PEDCo-Environmental Specialists, Inc.
Suite 13, Atkinson Square
Cincinnati, Ohio 45246
1 '•l
under contract to 0 0 i '
Research Triangle Institute
Research Triangle Park, North Carolina 27711
Contract No. 68-02-0607, Task No. 5
EPA Project Officer: John W^lufleV"•" " r ••'! P-^tocilon Agency
Reg!c-- ••
250 5-;-' . ' -.•••.•;.? ,-^'
10 . C,Oi"D Prepared for - = !-"-;-
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT AND GENERAL COUNSEL
OFFICE OF GENERAL ENFORCEMENT
DIVISION OF STATIONARY SOURCE ENFORCEMENT
WASHINGTON, B.C. 20460
July 1973
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The Enforcement Technical Guideline series of reports is issued by the
Office of Enforcement and General Counsel, Environmental Protection Agency,
to assist the Regional Office in activities related to enforcement of im-
plementation plans, new source emission standards, and hazardous emission
standards to be developed under the Clean Air Act. Copies of Enforcement
Technical Guideline reports are available - as supplies permit - from Di-
vision Stationary Source Enforcement, Environmental Protection Agency,
Washington, D.C. 20460 or may be obtained, for a nominal cost, from the
National Technical Information Service, 5285, Port Royal Road, Springfield,
Virginia 22151.
This report has been reviewed by the Environmental Protection Agency and
approved for publication. Approval does not signify that the contents
necessarily reflect the views and policies of the Agency, nor does men-
tion of trade names or commercial products constitute endorsement or rec-
ommendation for use.
PUBLICATION NO. EPA-340/l-73-001-a
U,S. C.MV....V. . , ..;ction Agency
11
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This report was furnished to the Environmental Protection
Agency by Research Triangle Institute, Research Triangle
Park, North Carolina, in fulfillment of Contract No. 68-02-0607.
The contents of this report are reproduced herein as received
from the contractor. The opinions, findings, and conclusions
expressed are those of the author and not necessarily those
of the Environmental Protection Agency.
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ACKNOWLEDGMENT
This report was prepared for the Environmental Protection
Agency by PEDCo-Environmental Specialists, Inc., Cincinnati,
Ohio, under subcontract to the Research Triangle Institute,
Research Triangle Park, North Carolina. Mr. Timothy W. Devitt
was the PEDCo Project Manager. Principal authors of the report
were Mr. F.K. Zada, Mr. T. Briggs and Mr. Devitt.
Mr. Harry Hamilton was the Project Manager for the
Research Triangle Institute. The Research Triangle Institute's
report on the economic factors affecting compliance schedule
evaluation is available as a separate volume.
Mr. John Butler was the Project Officer for the
Environmental Protection Agency. The authors appreciate the
many contributions made to this study by Mr. Butler, Mr. Kirk
Foster, and other members of the Division of Stationary Source
Enforcement.
The majority of the data used to prepare the model
compliance schedules was provided by air pollution control
equipment manufacturers. The project team appreciates their
assistance on this study and particularly that of Research
Cottrell, Vulcan-Cincinnati and Buell Envirotech which provided
detailed case history data for control device installations
in several industries.
Mrs. Anne Cassel conducted the editorial review and Mr.
*
Chuck Fleming was responsible for the graphics and final
report preparation.
iv
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TABLE OF CONTENTS
SECTION PAGE
LIST OF FIGURES vi
LIST OF TABLES xvi
1.0 INTRODUCTION 1-1
2.0 COMPLIANCE SCHEDULE DEVELOPMENT 2-1
2.1 Compliance Schedule Format 2-1
2.2 Summary Schedules by Control Device 2-5
2.3 Contingencies Affecting Compliance Schedules 2-22
3.0 COMPLIANCE SCHEDULES FOR SELECTED INDUSTRIAL
SOURCES 3-1
3.1 Stationary Combustion 3-1
3.1.1 Coal-Fired Utility Boilers 3-1
3.1.2 Coal-Fired Industrial Boilers 3-8
3.2 Solid Waste Disposal 3-13
3.2.1 Municipal Incinerators 3-13
3.3 Evaporation Sources 3-19
3.3.1 Surface Coating 3-19
3.3.2 Petroleum Storage 3-27
3.4 Chemical Processes 3-30
3.4.1 Nitric Acid 3-30
3.4.2 Phosphoric Acid 3-36
3.4.3 Sulfuric Acid 3-42
3.4.4 Paint and Varnish 3-52
3.4.5 Soap and Detergents 3-55
3.5 Agricultural Products 3-61
3.5.1 Grain Handling and Processing 3-61
3.5.2 Phosphate Fertilizer 3-72
3.6 Primary Metallurgical Processes 3-79
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SECTION PAGE
3.6.1 iXetsilurgicai Coke 3-79
3.6.2 Iron and Steel 3-91
3.6.3 Primary Aiir/ainum 3-99
3.6.4 Ferroalloys 3-107
3.7 Secondary Metallurgical Processes 3-113
3.7.1 Aluminum 3-113
3.7.2 Brass and Bronze 3-122
?.7.3 Steel 3-126
3.7.4 Gray Iron 3-131
3.7.5 Lead Smelting 3-135
3.7.6 Zinc Smelting 3-141
3.7.7 Magnesium Smelting 3-145
3.7.8 Core Making and Sand Handling 3-149
3.8 Mineral Industries 3-153
3.8.1 Portland Cement 3-153
3.8.2 Lime 3-159
3.3.3 Phosphate Pock 3-164
3.8.4 Glass 3-167
3.8.5 Fiber Glass 3-174
3.8.6 Asphalt Batching 3-180
3.8.7 Asphalt Roofing 3-185
3.8.8 Concrete Patching 3-190
3.9 Petroleum Industry 3-194
3.9.1 Petroleum Refining 3-194
3.10 Pulp and Paper 3-205
3.10.1 Kraft Process 3-205
3.10.2 Sulfite Pulping 3-211
4.0 SUPPORTING DATA 4-1
4.1 Vendor Data 4-1
4.1.1 Quoted Delivery Schedules 4-1
4.1.2 Case Histories 4-7
4.2 Industrial Coiitec-cs 4-11
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LIST OF FIGURES
Figure Page
2.1 Compliance Schedule Chart 2-2
2.2 Schedule for Installation of Small Electrostatic
Precipitator Capacity under 300,000 CFM 2-9
2.3 Schedule for Installation of Large Electrostatic
Precipitator Capacity over 300,000 CFM 2-10
2.4 Schedule for Installation of Small Fabric Filter
under 200,000 ACFM 2-11
2.5 Schedule for Installation of Large Fabric Filter
Capacity over 200,000 CFM 2-12
2.6 Schedule for Installation of Low Energy Wet
Scrubber Capacity under 150,000 CFM 2-13
2.7 Schedule for Installation of High Energy Wet
Scrubber Capacity under 150,000 CFM 2-14
2.8 Schedule for Installation of a High Energy Wet
Scrubber System Capacity over 150,000 CFM 2-15
2.9 Schedule for Installation of an Afterburner .... 2-16
2.10 Schedule for Installation of Packaged Adsorption
System, Including Field-Erected Distillation
Unit 2-17
2.11 Schedule for Installation of Field-Erected
Adsorption System Including Distillation Unit ... 2-18
2.12 Schedule for Installation of High-Energy Air
Filter (HEAF) Unit 2-19
3.1.1 Coal-Fired Power Utility 3-2
3.1.2 Schedule for Installation of an Electrostatic
Precipitator For Particulate Pollutant Control.. 3-6
3.1.3 Schedule for Installation of a Wet Scrubber
for Particulate Pollutant Control on a Coal-
Fired Utility Boiler 3-7
vii
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Figure Page
3.1.4 Schedule for Installation of an Electrostatic
Precipitator for Particulate Pollutant Con-
trol on Coal-Fired Industrial Bcoler 3-11
3.1.5 Schedule for Installation o± a Wet Scrubber
for Particulate Pollutant Control on a Coal-
Fired Industrial Boiler 3-12
3.2.1 Municipal Incinerator Process 3-14
3.2.2 Schedule for Installation of a wet Scrubber
for Particulats Pollutant Control on a Municipal
Incinerator 3-17
3.2.3 Schedule for Installation of an Electrostatic
Precipitator for Particulate Pollutant Control
on a Municipal Incinerator 3-18
3.3.1 Surface Coating Operation with Afterburner
Control System 3-20
3.3.2 Surface Goatling Operation with Absorption Con-
trol System ". 3-20
3.3.3 Schedule for Installation of Field-Erected
Absorption System Including Distillation Unit
on a Surface Coating Operation for Hydrocarbon
Emissions Control 3-24
3.3.4 Schedule for Installation of a Packaged
Absorption System Including Field-Erected Dis-
tillation Unit on a Surface Coating Operation
for Hydrocarbon Emissions Control 3-25
3.3.5 Schedule for Installation of an Afterburner on
a Surface Coating Operatj on for Hydrocarbon
Emissions Control 3-26
3.3.6 Schedule for Installation of ~j.n Internal
Floater on an Existing Storage "ank for Hydro-
carbon Emissions Control 3-29
3.4.1 Flow Diagram of ftitric Acid Manufacture by the
Pressure Process, with Catalytic Tail Gas Con-
trol System , 3-31
3.4.2 Schedule for Installation of a Catalytic Re-
duction Unit with Waste Heat Recovery on a
Nitric Acid Plant for Nitrogen Oxide Emissions
Control 3-34
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Figure Page
3.4.3 Tentative Schedule for Installation of
Molecular Sieve Adsorption System of a
Nitric Acid Plant for Nitrogen Oxide
Emissions Control 3-35
3.4.4 Wet-Process Phosphoric Acid Plant 3-36
3.4.5 Thermal-Process Phosphoric Acid Plant 3-37
3.4.6 Schedule for Installation of Wet
Scrubber System on Phosphoric Acid Manu-
facturing Operation for Gaseous and
Particulate Fluoride Control 3-39
3.4.7 Schedule for Installation of High-
Pressure Mist Eliminator on Phosphoric
Acid Manufacturing Operation for Acid Mist
Emissions Control 3-40
3.4.8 Contact-Process Sulfuric Acid Plant
Burning Elemental Sulfur 3-42
3.4.9 Schedule for Modifying an Existing Sul-
furic Acid Plant to the Dual Absorption
Process for Sulfur Oxides Emission Control 3~47
3.4.10 Schedule for Installation of a Sodium
Sulfite Scrubbing System for Sulfur
Oxides Emission Control 3-48
3.4.11 Schedule for Installation of an Ammonia
Scrubbing System, Including Mist Elimina-
tor, on a Sulfuric Acid Plant for Sulfur
Oxides Emission Control 3-49
3.4.12 Tentative Schedule for Installation of a
Molecular Sieve Separation Process on a
Sulfuric Acid Plant for Sulfur Oxides
Emission Control 3-50
3.4.13 Schedule for Installation of a Mist
Eliminator on a Sulfuric Acid Plant for
Acid Mist Emission Control 3-51
3.4.14 Schedule for Installation of an Afterburner
on Paint or Varnish Operations for Hydro-
carbon Emissions Control 3-54
3.4.15 Soap Manufacture 3-55
ix
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Figure Page
3.4.16 Detergent Manufacture 3-56
3.4.17 Schedule for Installation of a Wet
Scrubber/Electrostatic Precipitator on a
Spray Drying lower for rarticulate
Pollutant Control 3-59
3.4.18 Schedule for Installation of Fabric
Filter on Biend;.ng and Packaging
Operations for Particuiate Pollutant
Control 3-60
3.5.1 Terminal Elevator 3-62
3.5.2 Soybean Processing 3-64
3.5.3 Flour Milling 3-65
3.5.4 Wet Corn Milling , 3-66
3.5.5 Feed Manufacturing 3-67
3.5.6 Schedule for Installation of Baghouse or
Self-Cleaning Screen Filter on Grain
Handling and Processing Sources for Par-
ticuiate Pollutant Control 3-70
3.5.7 Schedule for Installation of High-Energy
Cyclone on Grain. Handling and Processing
Sources for Particuiate Pollutant Con-
trol 3-71
3.5.8 Normal Superphosphate Plant 3-72
3.5.9 Triple Superphosphate Plant 3-74
3.5.10 Diammonium Phosphate Plant 3-75
3.5.11 Schedule for Installation, of a Wet
Scrubber on Phosphate Fertilizer Opera-
tion for Particuiate and Gaseous Fluoride
Emissions Control 3-78
3.6.1 Metallurgical Coke Manufacturing 3-81
3.6.2 Schedule for Installation of Coal Charg-
ing on the Main with Closed Coal Ports
for an Existing Battery 3-86
x
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Figure Page
3.6.3 Schedule for Installation of Pipeline
Charging System for an Existing
Battery 3-87
3.6.4 Schedule for Installation of a Hooded
Grind Car System for Control of Particu-
late Emissions During Pushing and
Quenching Operations 3-88
3.6.5 Schedule for Installation of Vacuum
Carbonate Scrubbing Process 3-89
3.6.6 Schedule for Installation of a Sulfur
Recovery Unit (Claus Plant) 3-90
3.6.7 Integrated Iron and Steel Facility 3-92
3.6.8 Compliance Schedule for Installation of
A High-Energy Wet Scrubber for Particulate
Pollutant Control 3-96
3.6.9 Compliance Schedule for Installation of
electrostatic precipitator for particulate
pollutant control 3-97
3.6.10 Compliance Schedule for Installation of a
Baghouse for Particulate Pollutant Control 3-98
3.6.11 Schedule for Installation of a Wet
Scrubber on a Primary Aluminum Reduction
Operation for Particulate Pollutant and
Fluoride Emissions Control 3-104
3.6.12 Schedule for Installation of a Fabric
Filter on a Primary Aluminum Reduction
Operation for Particulate Pollutant Con-
trol 3-105
3.6.13 Schedule for Installation of an Electro-
static Precipitator on a Primary
Aluminum Operation for Particulate
Pollutant Control 3-106
3.6.14 Schedule for Installation of a Wet
Scrubber on a Ferroalloy Furnace for Par-
ticulate Pollutant Control 3-110
3.6.15 Schedule for Installation of a Fabric
Filter with Pre-Cooler on a Ferroalloy
Furnace for Particulate Pollutant Control 3-111
XI
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Figure Page
3.6.16 Schedule for Installation of an Electro-
static Precipitator on a Ferroalloy
Furnace 3-112
3.7.1 Secondary Aluminum Process 3-114
3.7.2 Schedule for Installation of a Fabric
Filter or Fabric Filter/Afterburner
Control System for Partiiculate Pollutant
Control 3-118
3.7.3 Schedule for Installation of a Wet
Scrubber or Wet Scrubber/Afterburner Con-
trol System for Particulate Pollutant
Control 3-119
3.7.4 Schedule for Installation of an After-
burner for Control of Hydrocarbon and
Combustible Particulate Emissions 3-120
3.7.5 Schedule for Installation of Custom-
Designed Fabric Filter for Particulate
Pollutant Control 3-121
3.7.6 Schedule for Installation of a Fabric
Filter on a Brass and Bronze Foundry
for Particulate Pollutant Control 3-125
3.7.7 Schedule for Installation of a Fabric
Filter on a Steel Foundry Furnace for
Particulate Pollutant Control 3-128
3.7.8 Schedule for Installation of a Wet
Scrubber on a Steel Foundry Furnace for
Particulate Pollutant Control 3-129
3.7.9 Schedule for Installation of a Custom-De-
sign Fabric Filter for Particulate
Pollutant Control 3-130
3.7.10 Schedule for Installation of a Fabric
Filter/Afterburner Control System for
Particulate Pollutant Control 3-133
3.7.11 Schedule for Installation of a High-
Energy Wet Scrubber System for Par-
ticulate Pollutant Control 3-134
Xll
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Figure Page
3.7.12 Lead Reverberatory Furnace 3-136
3.7.13 Schedule for Installation of a Wet
Scrubber System on Lead Smelting Furnaces
for Particulate Pollutant and Gaseous
Emissions Control 3-139
3.7.14 Schedule for Installation of an Afterburner/
Baghouse System on Lead Smelting Furnace
for Particulate Pollutant Control 3-140
3.7.15 Schedule for Installation of a Fabric
Filter on a Zinc Smelting Furnace for
Particulate Pollutant Control 3-144
3.7.16 Schedule for Installation of a Fabric
Filter on a Magnesium Smelting Furnace for
Particulate Pollutant Control 3-147
3.7.17 Schedule for Installation of a Wet
Scrubber System on a Magnesium Smelting
Furnace for Particulate Pollutant Con-
trol 3-148
3.7.18 Core Making and Sand Handling 3-149
3.7.19 Schedule for Installation of an After-
burner on a Core Baking Oven for Hydro-
carbon Emissions Control 3-151
3.7.20 Schedule for Installation of a Fabric
Filter on a Sand Handling System for
Particulate Pollutant Control 3-152
3.8.1 Cement Manufacture 3-154
3.8.2 Compliance Schedule for Installation of a
Fabric Filter on a Cement Kiln for Par-
ticulate Pollutant Control 3-157
3.8.3 Compliance Schedule for Installation of
an Electrostatic Precipitator on a
Cement Kiln for Particulate Pollutant Con-
trol 3-158
3.8.4 Manufacture of Lime and Limestone Products 3-160
3.8.5 Schedule for Installation of Wet
Scrubber on Lime Manufacturing Operation
for Particulate Pollutant Control 3-162
Xlll
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Figure Page
3.8.6 Schedule for Installation of Fabric
Filter on Lime Manufacturing Operation
for Particulate Pollutant Control 3-163
3.8.7 Phosphate Rock Processing 3-164
3.8.8 Schedule for Installation of Fabric
Filter on Phosphate Rock Processing
Operation for Particulate Pollutant
Control 3-166
3.8.9 Soda-Lime Glass Manufacture 3-168
3.8.10 Schedule for Installation of a Custom-
Designed Fabric Filter on a Glass Furnace
for Particulate Pollutant Control 3-171
3.8.11 Schedule for Installation of High-Energy
Venturi Scrubber on Glass Furnace for
Particulate Pollutant Control 3-172
3.8.12 Fiber Glass Production 3-174
3.8.13 Schedule for Installation of a High-
Energy Wet Scrubber on Fiber Glass Form-
ing and Curing Operations for Particulate
Pollutant Control 3-176
3.8.14 Schedule for Installation of a High-
Energy Air Filter (HEAP) Unit on Fiber
Glass Forming and Curing Operations for
Particulate Pollutant Control 3-177
3.8.15 Schedule for Installation of an Afterburner
on Fiber Glass Forming and Curing Opera-
tions for Particulate Pollutant Control.. 3-178
3.8.16 Asphalt Batch Plant 3-181
3.8.17 Schedule for Installation of a Wet
Scrubber on an Asphalt Batch Plant for
Particulate Pollutant Control 3-183
3.8.18 Schedule for Installation of a Fabric
Filter on an Asphalt Batch Plant for Par-
ticulate Pollutant Control 3-184
3.8.19 Manufacture of Asphalt Roofing Materials. 3-186
XXV
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Figure Page
3.8.20 Schedule for Installation of an After-
burner on an Asphalt Roofing Operation
for Particulate Pollutant Control 3-188
3.8.21 Schedule for Installation of a HEAP
Unit on Asphalt Roofing Operation for
Particulate Pollutant Control 3-189
3.8.22 Wet-Concrete Batch Loading Operation .... 3-190
3.8.23 Schedule for Installation of a Fabric
Filter on a Concrete Batch Plant for
Particulate Pollutant Control 3-192
3.9.1 Intermediate Refinery 3-196
3.9.2 Complete Refinery 3-196
3.9.3 Schedule for Installation of an Amine-
Treater-Sulfur Plant for Hydrogen Sulfide
Emission Control 3-201
3.9.4 Schedule for Installation of a Tail Gas
Desulfurization Unit for Sulfur Oxide
Emissions Control 3-202
3.9.5 Schedule for Installation of an Amine
Treater, a Sulfur Plant and a Tail Gas
Desulfurization Unit 3-203
3.9.6 Schedule for Installation of an Electro-
static Precipitator for Particulate
Pollutant Control 3-204
3.10.1 Kraft Process 3-206
3.10.2 Schedule for Installation of an Electro-
static Precipitator on Recovery Boiler
in Pulp Mill for Particulate Pollutant
Control 3-209
3.10.3 Schedule for Installation of a Wet
Scrubber on Lime Kiln and Smelt Dissolv-
ing Tank in a Kraft Mill for Particulate
Pollutant Control 3-210
xv
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Figure Page
3.10.4 Spent Sulfite Liquor Recovery System 3-212
3.10.5 Schedule for Installation of a Spent
Sulfite Liquor Recovery System in a Pulp
Mill 3-214
4.1 Case-History Data for Electrostatic
Precipitators 4-10
4.2 Schedule for Installation of High-Energy
Wet Scrubber on Steel Furnace 4-14
4.3 Schedule for Installation of Electrostatic
Precipitator on Cement Kiln 4-16
4.4 Schedule for Installation of Custom-Designed
Fabric Filter on Gray Iron Cupola 4-18
xvi
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LIST OF TABLES
Table Page
2.1 Description of Activities on Compliance
Schedule Chart 2-3 , 2-4
2.2 Compliance Schedule Requirements Explanation of
Activities on Chart 2-6 - 2-8
2.3 Estimated Schedule Of Engineering Drawings
Activity Designation (L-0) 2-20
4.1 Vendor Delivery Schedules for Electrostatic
Precipitators 4-2
4.2 Vendor Delivery Schedules for Fabric Filters .. 4-3
4.3 Vendor Delivery Schedules for Wet Scrubbers .... 4-5
4.4 Vendor Delivery Schedules for High-
Pressure Fans 4-6
4.5 Vendor Delivery Schedules for Ancillary
Equipment 4-8
xvii
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1.0 INTRODUCTION
On August 14, 1971, the Administrator of the Environmental
Protection Agency promulgated regulations in the Federal
Register, 40 CFR Part 51, specifying minimum requirements for
the State Air Quality Implementation Plans required by Section
110 of the Clean Air Act. As mandated by Section 110 and
specified in these regulations, implementation plans must
include emission limitations adequate to attain and maintain
national ambient air quality standards and require compliance
schedules from all sources subject to the emission limitations.
These schedules must provide for compliance as expeditiously
as practicable for sources in air quality control regions
where the national primary standards are being exceeded or
within a reasonable period of time for sources in regions where
only the secondary air quality standards are being exceeded.
To provide aid for use in evaluating compliance schedules,
this study was undertaken to determine the time required to
install air pollution control equipment in an expeditious
manner on selected industrial sources. The results of this
study can also be used to develop federal compliance schedules
where states have failed to submit approvable schedules to
EPA. In addition, this study should prove useful to the EPA
1-1
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Regional Offices developing schedules to be included in
enforcement orders issued to air pollution sources under the
authority of Section 113 of the Clean Air Act.
Industries selected for this study were chosen from those
listed in Appendix C, 40 CFR, Part 51, and from those listed
in the "Compilation of Air Pollution Emission Factors"
published by the EPA Office of Air Programs. From these
listings, industries were selected which met all three of the
following criteria: (1) emit particulates, sulfur dioxide,
nitrogen oxides, carbon monoxide, or hydrocarbons; (2) could
achieve compliance with application of reasonably available
control technology within a 36-month period; and (3) were
significant on a nationwide basis both with respect to emissions
potential and number of sources. Thirty-four industries were
selected by application of these criteria, and schedules were
prepared indicating the time required to control major emission
sources within each industry to levels consistent with available
control technology as defined in Appendix B, 40 CFR, Part 51.
Manufacturers and users of air pollution control equipment
supplied most of the information used to develop the schedules.
Three of the manufacturers — Research Cottrell, Buell Envirotech
and Vulcan-Cincinnati — also provided detailed case histories.
1-2
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Preliminary schedules prepared using the manufacturers' data
were subjected to engineering evaluation. The resulting
tentative schedules were reviewed with representatives from
the concerned industries and with EPA personnel. On the basis
of these reviews, the schedules presented herein were developed,
It is emphasized that these schedules should be considered
as guidelines. Many mitigating factors can affect the schedule
of any individual installation. These factors include on-site
problems such as space limitations, inclement weather, and
lack of needed utilities; logistical problems such as delays
in equipment delivery caused by special orders, backlog of
orders, and unavailability of large motors and/or fans; and
design problems caused by lack of engineering data for some
applications. To the limited extent possible, such factors
were considered in preparation of the schedules.
Section 2.0 describes the compliance schedule format,
presents summary schedules by type of control device, and
describes the technical and economic contingencies that can
affect installations. Section 3.0 presents brief process
descriptions and describes emission sources and emission
characteristics for each of the thirty-four industries studied.
1-3
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The types of control systems commonly used are identified, and
some of the problems encountered in achieving reliable, high-
efficiency emissions control are briefly discussed; sources
of additional information are also listed. Time schedules are
presented for installation of selected control methods.
Section 4.0 describes the study approach and summarizes the
supporting data used to prepare the schedules.
1-4
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2.0 COMPLIANCE SCHEDULE DEVELOPMENT
2.1 Compliance Schedule Format
Figure 2.1 depicts the chart used to identify the
various steps required to complete installation of a control
system and the time required for such steps. The increments
of progress (milestones) presented on this chart are the
same as those defined in 40 CFR, Part 51:
(1) Date of submittal of the final control plan to the
appropriate air pollution control agency;
(2) Date by which contracts for emission control systems
or process modifications will be awarded; or date by which
orders will be issued for purchase of component parts to
accomplish emission control or process modification;
(3) Date of initiation of on-site construction or
installation of emission control equipment or process change;
(4) Date by which on-site construction or installation
of emission control equipment or process modification is to
be completed; and
(5) Date by which final compliance is to be achieved.
The activities required for achieving these milestones,
also shown on the compliance schedules chart, are described
in Table 2.1.
In development of the time schedules, it was assumed
that the steps prior to Milestone 1 are essentially completed.
Since emission regulations were generally adopted in early 1972,
2-1
-------
Figure 2.1 Compliance schedule chart.
fO
i
= Milestones
*• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Dote of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction {system tie-in)
4-5 Startup, shakedown, preliminary source test
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Table 2.1 DESCRIPTION OF ACTIVITIES ON COMPLIANCE SCHEDULE CHART
ACTIVITY
CODE
ACTIVITY
DESCRIPTION
DETAILS OF ACTIVITY
to
I
G-l
I-H
H-J
J-2
2-K
Finalize plans and specification
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
K-L
L-M
L-0
0-P
Review and approval of assembly
drawings
Vendor prepares fabrication
drawings
Prepare engineering drawings
Procure construction bids
The control system is specified in sufficient detail for control equip-
ment suppliers and contractors to prepare bids. A final control plan
summarizing this information is prepared for submittal to the
appropriate agency.
Specifications for the control device are disseminated and bids from
suppliers are requested.
Bids are evaluated and suppliers are selected.
The successful bidder is notified and contract is signed.
The vendor prepares the assembly drawings for the control device. -For
the smaller and common types of devices, standard shop drawings which
apply to several size ranges may be used with the appropriate dimensions
underlined or otherwise indicated. For larger devices, it may be neces-
sary to prepare drawings specifically for the project at hand. The
drawings are mailed to the client for his approval before fabrication
drawings are started.
The client reviews the assembly drawings and gives approval to begin
fabrication drawings. The client also uses the assembly drawings to
prepare the necessary engineering drawings.
Upon receipt of approval from client to proceed with construction of the
control device, the vendor prepares fabrication or shop drawings which
will be used in the manufacturing and assembling of the control equip-
ment.
Based on data from the vendor's drawings and previous engineering studies,
the client (or his consultant) prepares architectural and mechanical
drawings for modifications and additions to the plant to accommodate the
emission control system.
The bid package specifying the scope of work and specifications of
materials and including the drawings is mailed to selected contractors.
During this period, the contractors prepare their bids for material
and labor to construct all duct work, piping, utilities, etc. and for
installation of the control device.
-------
Table 2.1 (Continued)
ACTIVITY
CODE
ACTIVITY
DESCRIPTION
DETAILS OF ACTIVITY
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-4 Install control device
R-4 Complete construction (system
tie-in)
4-5 Startup, shakedown, emissions test
The client or his consultant evaluates the bids and selects the
contractor.
The selected contractor is notified and the contract siopsd.
Using the architectural and mechanical drawings, the contractor
begins his work. He> usually subcontracts electrical or duct work to
specialists.
The control device (or the final components) arrives on site. The con-
tractor should be prepared for installation and tie-in with other piping,
duct- work, and electrical switch gear. Field assembled nulls v;.U] -artivf-
in sections and be erected at the site. Internals such as catalysts,
activated carbon, and bag filters are also installed during this time.
Tying bhe control device into the system requires shutdown of the process
be scheduled for minimum disturbance of the operation. The contractor's
responsibility usually ends at this point, when the client and the vendor's
representative accept the construction as complete.
The process is brought back on-line and any unforeseen problems with the
control system are resolved. Emissions testing may be performed to
determine whether performance of the system is acceptable.
-------
industries have had ample time to complete their problem
evaluations, emission tests, and technical and economic
evaluations of control alternatives. Thus the time schedules
were started at the point of finalizing control system plans
and specifications for submission to the appropriate air
pollution control agency.
Table 2.2 identifies the typical times required to complete
the various activities on the schedule and the factors that
influence these times.
2.2 Summary Schedules by Control Device
Schedules for the expeditious installation of the most
commonly used air pollution control devices are shown in
Figures 2.2 through 2.12. Several sources of information were
used to prepare these schedules. Promised delivery and
installation times stated by control device suppliers were
cross-checked with companies having recently purchased such
equipment. In many cases, promised delivery times were
not met. Analysis of case-history data provided by three
control device manufacturers substantiated the need for
modifying the "promised" or expected schedules currently
quoted by vendors. On the other hand, case-history data
also required qualification, since it did not reflect
expeditious schedules, partly because of lack of enforcement
2-5
-------
Table 2.2 COMPLIANCE SCHEDULE REQUIREMENTS
EXPLANATION OF ACTIVITIES ON CHART
ACTIVITY COMMENTS
G-l Two to six weeks are allocated for finalizing
plans and specifications. The variation
depends on the magnitude and complexity of
the project.
1-H A minimum time of four weeks is required to
procure bids on small jobs. A maximum of twelve
weeks is allowed for large non-standard units
since initial vendor quotations frequently do
not match bid specifications, and further
contacts with each bidder are required.
H-J Two to five weeks is allocated for evaluating
control device bids. Small, privately owned
firms will require little time; in large
corporations, bid evaluation often involves
several departments and more time is required.
J-2 A minimum of two weeks is allocated for preparing
the final control papers and awarding contracts
for the control device and major components.
This activity takes longer in large corporations
where examination and approval of the contract
by several departments is required.
2-K Depending on the complexity and originality
of the design, the time required by the vendor
to submit assembly drawings, which show
dimensions, orientations, and weights, could
vary from weeks to months. Two to six weeks is
allowed for this activity on the basis of
consultation with suppliers of control equipment.
K-L One to two weeks is sufficient for review and
approval of assembly drawings. The longer
time is required for any delay in approval as
a result of revisions and modifications.
L-M Three to eight weeks is normally required
for the vendor to prepare the shop or
fabrication drawings for fabrication and assembly
of the control device. These figures are based
on information supplied by vendors of pollution
control equipment.
2-6
-------
Table 2.2 (Continued)
ACTIVITY COMMENTS
M-N On small control devices that can be
shop-assembled, this activity represents
the fabrication, assembly of components, and
delivery of the control unit to the site.
On large field-erected control devices, time
shown for this activity indicates the fabrication
and delivery of the first components (structural)
to the site. Delivery of remaining components
continues throughout the construction phase.
Duration given for this activity is based on
consultation with manufacturers of control
devices.
L-0 In this activity the client (or his consultant)
prepares an engineering drawings package for use
by the construction company for pouring
foundations, installing structures, ductwork,
electrical equipment, and any other items not
supplied with the control device. These drawings
also show the location and tie-in of the control
device. Estimated engineering times for each
major type of control device are shown in
Table 2.3.
0-P Engineering drawings and specifications
constitute the bulk of the construction bid
document. A minimum of four weeks is allocated
for obtaining bids from the contractors.
P-Q Construction bids are evaluated and the success-
ful bidder selected. Two weeks is allowed for
this activity.
Q-3 Construction contract is prepared. In large
corporations, it is reviewed and approved by
several departments before submission to the
contractor.
3-N This activity primarily consists of site
clearance, pouring of the foundation, erecting
structural members, installing ductwork, and
installing auxiliary equipment.
2-7
-------
Table 2.2 (Continued)
ACTIVITY COMMENTS
N-R For this activity, essentially an extension
of the construction work, the time is allocated
primarily for installation of a shop-assembled
(or modular) control device. For a field-erected
unit, it represents the time required to complete
the installation of components as they arrive
on site. These installation times are based on
data supplied by vendors and substantiated by
users.
R-4 Two to six weeks is allocated for tie-in.
In large installations, where the process
cannot be conveniently shut down at the end
of the construction phase, longer times may be
required.
4-5 Startup, shakedown, and preliminary emissions
testing would require from two weeks for a
small and simple installation to about eight
weeks for a large and complicated system.
2-8
-------
Figure 2.2 Schedule for installation of small electrostatic
precipitator capacity under 300,000 CFM.
IV)
I
= Milestones
•• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency
2 Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ACTIVITIES
Designatiot
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and speculations
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.3 Schedule for installation of large electrostatic
precipitator capacity over 300,000 CFM.
to
I
o
= Milestones
• = Activity and duration in weeks
MILESTONES
1 Date of submirtal of final control plan to appropriate agency *
2 Date of award of control device contract.
3 Date of initiation of on-«ite construction or installation of emission control equ!pn~ei.t.
4 Date by which on-sife construction or installation of emission control equipment 11 completed.
5 Date by which final compliance is achieved^
E_L APSE D TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-f
F--G
G-l
1-H
H-J
J-2
2-K
\QT
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule 'or agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bid-
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate cor>trol device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.4 Schedule for installation of small fabric filter
under 200,000 ACFM.
= Milestones
-—*• - Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment,
4 Da*e by which on-site construction or installation of emission control equipment is completed
5 Ootr by -vhich final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source rests
Evaluate control alternatives
Commft funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency -eview and approval
Fi'-'iti?^ plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
*'~L Revie/* a" ' upproval of assembly drawings
L-M Vendor prepares fabrication drawriys,
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction Hds
P-Q Fvaluate construc*
-------
Figure 2.5 Schedule for installation of large fabric filter
capacity over 200,000 CFM.
K)
!
\->
tv>
•REI
= Milestones
•• = Actlv'ly and duration in weeks
MITSTONES
ELAPSED TIME (WEEKS)
1
2
3
4
5
ACjj_VIJIES
Design -il i on
A-C
A-B
C-D
D-E
t-F
F-G
G-l
1-H
H-J
J-2
2-K
Doie of subrnittal of fiml control plan to appropriate agency*
Date of award of control device contract.
Dote of initia-'on of on-site construction or installation of emission control equipment,,
Date by which on-site construction or installation of emission control equip- en I is completed..
Date b, which final compliance is achieved.
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembl/ drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate conhol device
L-O Prepare engineering drawings
O-P Procure construction b'J
P-Q Evaluate conb1 Action bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.6 Schedule for installation of low energy
wet scrubber capacity under 150,000 CFM.
NJ
i
H
U>
= Milesfones
*• - Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency ,
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment,
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Review and appro/al o' assembly drawings
Vendor prepares PabricaHon -linwings
Fabricate .oMro1 device
prt;pare engineering drawings
Procure construc-'on o'ds
Evaluate construction bids
Award construction contract
On-site construction
Install control device
Complete construction (system tie-''r
Startup, shakedown, preliminary source test
-------
Figure 2.7 Schedule for installation of high energy
wet scrubber capacity under 150,000 CFM.
K)
I
2
- Milestones
- Activity end durotion in weeks
MILESlONES
1
AC]_l_VITiy>
Desijiiut'on
A C
A-B
C-D
D-E
r -I
F-G
G-l
1-H
H-J
J-2
2-K
Date of submitlol of final control plan fo approoriate ouency*
Date of aword of control device conhact.
Dale of initiation of on-site construction or installation cf emission control equipment
Dafp by which on-site constrjction or installation if emission control equipment is competeds
Dafe by which final compliance is achieved.
Preliminary investigation
Sour< o ht-sts
f 'atuate control altei'-iatives
Commit funds for total program
I'lppare preliminary control plan and con-,p!ionce
'chedule for agency
Agency review and approval
Finalize plans and specifications
Procure conho' device bids
tvaluate control vice bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of awmbly drawing!
L-M Vendoi prepares fabrication drawings
M-N Fabricate rorrrol device
L-O prepare e igineering drawings
O-P Procure cDnstruc'ion bids
P-Q Evaluate co:> *t jetton bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete constiuction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.8 Schedule for installation of a high energy wet scrubber system
capacity over 150,000 CFM.
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipments
Date by which on-site construction or installation of emission control equipment is completed0
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.9 Schedule for installation of an afterburner.
I
H
Ol
- Milestones
1
9
3
4
5
ACTJVIIIES
Design uli in
A-C
A-B
C-l-
[>-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
•*- = Activity and duration in weeks
Dale of submittol of final control plan to appropriate agency,,
Date of award of control device contiart.
Date of initiation of on-site construction or installation of emission control equipment 0
pote by vSich op-site construction or insto!!ofion of emission control equipment ts completeJc
Date by whic!1! final compliance is achieved *
f LAPSF.D TIME (WEEKS)
Preiim'inaiy invesriyutton
Source te^H
Fvad'o'r cc-'-t'ol alternatives
lomm'it funds for total program
Prepaie preliminary control plon and compliance
schedule foi a^onc;.
Agency review and approval
rinuli7e plans and sprcificatio"s
Pro;ore control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designator
K-L Review and appicival of nwembly drawings
L-M Vendor prepares fubiicarion drovings
M-N Fut>ricate coni T! devk».
L-O Prepaie engineering drawings
O-P Procure conitruction bidt
P-Q Evaluate constntciion h-ds
Q-3 Award con^ti jction contrjc1
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.10 Schedule for installation of packaged adsorption system,
including field-erected distillation unit.
,
0—•©-©-©-
to
I
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agenc/
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equit»"ienf
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
• ocure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
y \ Review ar > Approval ~>r assembly drawings
L-M v'endoi prepares fabrication drawings
M-N fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Fvaluate construction bids
Q -3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 2.11 Schedule for installation of field-erected
adsorption system, including distillation unit.
jS
I
H1
00
= Milestones
*• = Activity and duration in weeks
MII_Ff.!C)iJES
1 Date of Hibr.iiltal of final control plan to appropriate aqency*
2 Daio of aworu of coniiol device contract.
3 Date of initiation of on-site construcrion or installation of emission control equipment*
4 Dote 'y ,,1,'ch on -site construction or installation of emission control equipment is complete,-.-)„
5 i>ilr l., which final compliance is achieved .
ELAPSED TIME (WEEKS)
ACTIVITIES
>X ./i^notion
A-C
A-B
C-D
n-F
F-r
F-G
G- '
1-H
H-J
J-2
2-K
Prelimina'> investigation
Souixe !^sts
T o1 "i*1/ f ^rl^lol alternatives
Co.Ttrn'1" funds for total program
?!•' -jrt. preliminary control plan and compliance
sc duU "*>t agency
A^cur/ review and approval
F'na!l7e plans and specifications
Pi o- ure ,ci»trol device bids
Iv-iK'aie control device bids
AV ot. ot device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawing^
L-M Vendor prepares fabrirotion drawings
M-N Fabricate control device
L-O ^rcpare engineering drav ings
O-P Prorure construction bids
P-Q Lvu'uote construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source tesf
-------
Figure 2.12 Schedule for installation of
high energy air filter (HEAP) unit.
M
I
= Milestones
•• = Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency 0
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
1
2
3
4
5
ACTIVITIES
Designation
A-C Preliminary investigation
A-B Source tests
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare preliminary control plan and compliance
schedule for agency
F-G Agency review and approval
G-l Finalize plans and specifications
1 -H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Table 2.3 ESTIMATED SCHEDULE OF ENGINEERING DRAWINGS
ACTIVITY DESIGNATION (L-0)
CONTROL DEVICE
Electrostatic
Precipitator
Electrostatic
Precipitator
Fabric Filters
Fabric Filters
High Energy Wet
^ Scrubber
1 . ...
o High Energy Wet
Scrubber
Solvent Recovery
Unit
Solvent Recovery
Unit
Afterburner
High Energy Air
Filter
SIZE
Small
Large
Small
Large
Small
Large
Shop
Assembled
Field
Erected
Thermal/
Catalytic
PR&JECf
DESIGN
(1)
40 hrs
80 hrs
40 hrs
80 hrs
'40 hrs
40 hrs
40 hrs
40 hrs
40 hrs
40 hrs
LAV6UT
DRAWINGS
(2)
2
2
2
2
2
2
1
2
2
2
STRUCTURAL
DRAWINGS
(3)
1
1
1
1
2
2
2
2
1
1
FfiONDAflON
DRAWINGS
(4)
1
1
1
1
1
1
1
1
2
2
MfiCHAJllCAL
DRAWINGS
(5)
3
3
3
3
6
6
3
6
1
1
ELECTRICAL <
DRAWINGS
(6)
1
1
1
1
1
I
1
1
1
1
PACKAGE
(7)
40 hrs
80 hrs
40 hrs
80 hrs
40 hrs
40 hrs
40 hrs
40 hrs
40 hrs
40 hrs
• BS^8)
(8)
7 weeks
10 weeks
7 weeks
9 weeks
10 weeks
10 weeks
6 weeks
10 weeks
6 weeks
6 weeks
(a) Elapsed time is computed by multiplying the total of drawings in Columns (2) and (5) by 40 hours and adding to the
total figures shown in Columns (1) and (7)/ then dividing by 40 hours to obtain the time in weeks.
-------
pressure to install the devices in a prompt manner. Many
case histories also included several specification change-
orders by the customer, which delayed fabrication and delivery
of the control device.
It is emphasized that these composite schedules are
based on somewhat arbitrary break points in capacities (ACFM);
within each size range, significant variations in elapsed
time can occur. A number of factors influencing the delivery
and construction phases of these schedules may have more effect
on the final schedule than the size of the control device:
(a) special designs, which may require new fabrication drawings
and different fabrication procedures; (b) special materials of
construction; (c) limited space, necessitating unusual control
system configuration or moving of process equipment;
(d) extensive modifications of the process to accommodate the
emission control system; (e) type of contract — erected,
non-erected, turn-key; and (f) type of unit — shop-fabricated,
modular, or field-erected.
Although these schedules are necessarily more general
and less precise than those presented in Section 3.0, they
should provide reasonable guidelines for evaluating or developing
compliance schedules for those sources no4" de^cr-; -ed in
Section 3.0.
2-21
-------
2.3 Contingencies Affecting Compliance Schedules
The elapsed time of these compliance schedules represents
the "expeditiously as practicable" time needed to install
control equipment to achieve compliance with air pollution
regulations. Although the phrase "expeditiously as practicable"
defies precise definition, it generally refers to the minimum
time during which it is possible for operators of a facility
to attain compliance, considering lead times for engineering
design, contracting, construction, installation and startup,
and considering special problems in locating or operating
control equipment. Economic factors are considered of
secondary importance. It was assumed that the design and
construction work is performed during normal working hours;
thus the schedules may be shortened by overtime work. The
elapsed times shown on the schedules may increase as a result
of a variety of unforeseen problems that may occur in the
activity steps shown in Figure 2.1. Potential problems, by
activity, include the following:
Preparation of Engineering Drawings (L-O): Backlogs of
engineering work at the firm's engineering department or
consulting firm may delay assignment of engineers and draftsmen
to the project. This may not cause a delay in the overall
schedule as long as activities along L-3-N are of lesser
duration than those along L-M-N.
Fabrication of Control Device (M-N); Delays in fabrication
could result from backlog of orders at the shop, union strike,
shortage of special material, change in specifications by the
customer, and delay in customer approval of vendor's drawings.
2-22
-------
On large installations, where delivery times for air pollution
control devices are usually long, any delay in this activity
will directly affect the overall schedule.
On-Site Construction (3-N); This activity is susceptible
to delays resulting from lack of skilled labor at the needed
times, union strikes, vandalism, theft, severe weather, and
shortage of material.
Install Control Device (N-R); Installation of the control
device is essentially an extension of the construction activity
and is subject to the same contingencies. On retrofit jobs
where lay-down space is limited, the arrival of material on
site might have to be phased and construction would proceed
at a slower pace.
Complete Construction and System Tie-in (R-4); The
longest delay in this activity could result from the inability
to shut down the process to make the needed tie-ins, because
shut down would cause severe economic or other losses. On
large or critical operations, tie-in time could be minimized
by installing blinded tie-in points during the early part of
the construction phase.
Startup, Shakedown, Preliminary Emissions Testing (4-5) :
Delays in startup could be due to shortage of replacement
parts, equipment malfunction, improper equipment design, or
lack of available control manufacturer personnel to shakedown
the unit. On new processes, startup and emissions testing
could be delayed indefinitely while awaiting the construction,
startup, and debugging of new process or boiler equipment.
2-23
-------
3.0 COMPLIANCE SCHEDULES FOR SELECTED INDUSTRIAL SOURCES
3.l Stationary Combustion
3.1.1 Coal-Fired Utility Boilers
Process Description - Individual coal-fired utility boilers
range in size from small units generating about 20 MW of power
to units generating over 1000 MW. The smaller units are
usually operated for peak loading (i.e. to generate the
additional power needed during peak power usage hours) whereas
the larger boilers are usually operated continuously to provide
the base load. At large power generating stations with several
boilers, generating capacities can reach several thousand
megawatts.
The overall process for power generation at a coal-fired
utility is shown schematically in Figure 3.1.1. Coal is
usually received by barge or rail, sized, and then fired into
the furnace; the heat from combustion is used to produce steam
for generating power. Most coal-fired utilities use either
pulverized coal or cyclone-fired boilers, the pulverized-coal-
fired units vastly predominating. Almost all units in current
use are equipped with some type of device for fly ash control.
Atmospheric Emissions - Sources of particulate emission include
the coal receiving and handling operations, the furnace flue
3-1
-------
CO
C02
02
N2
NOx
SOx
PARTICULAR
CASTS TO ATMOSPHERE
UJ
1
NJ
UN BURNED
COAL
DUST
HOPPER CAR
SARGE OR
STORAGE PILE
CRUSHER
CONTROL
DEVICE
CLEANOUT
AIR POLLUMON
CONTROL
DEVICE
AIR HEATER
ECONOMIZER
SUPER HEATER
WATER
POLLUTION
SALINE WATER
SOLIDS
SLUDGE
LIQUID OR SOLID V/ASTC
TO WATER SEPARATING DEVICE FOR
TREATMENT OR TO DRAINAGE AREA
Figure 3.1.1 Coal-fired power utility.
-------
gases, and the ash disposal operations. Of these, the fly ash
contained in the flue gases represents the largest particulate
emission sources. The flue gases also can contain substantial
amounts of sulfur oxides and nitrogen oxides.
Pulverized-coal-fired boilers generally emit, as fly ash,
between 75 and 85 percent of the ash content of the coal. For
example, a unit burning coal having 10% ash content emits
approximately 160 pounds of fly ash per ton of coal burned.
Cyclone-fired units emit considerably less, approximately 10%
of the total ash content of the coal; a unit burning coal having
10% ash content emits approximately 20 pounds fly ash per ton
of coal burned.
Control Systems - Electrostatic precipitators have been used
almost exclusively for high-efficiency particulate control.
These devices are capable of operating with collection effi-
encies of more than 99 percent. In design of the precipitator,
particular attention must be paid to the sulfur content of
the coal and expected precipitator operating temperature;
both parameters influence fly ash resistivity, which in turn
directly affects collection efficiency.
Within the last few years, wet scrubbers have also been
installed to control particulate emissions from coal-fired
boilers. Usually such installations are made in anticipation
3-3
-------
of converting the scrubber system to collect both SO- and
particulate, not just particulate emissions.
Conversion from coal to oil or gas also effectively
reduces particulate and SO,., emissions.
Compliance Schedules - Figures 3.1.2 and 3.1.3 illustrate
expeditious schedules for installation of an electrostatic
precipitator and a wet scrubber for particulate control. No
schedule is shown for SO- and NO control since these systems
£ ^C
should be studied on an individual basis.
The elapsed time of these schedules may increase as a
result of delays in control device fabrication, staggering the
installation of several devices at one site, and a multitude
of startup problems. Because of their backlogs of orders, some
of the leading precipitator manufacturers can exceed the quoted
delivery schedules by as much as 16 weeks. Approximately 12
to 24 weeks is usually required for installation of each
additional precipitator after the first unit has been completed
because utilities must stagger the down times of the various
boilers to meet power generation requirements. Although this
additional time can be shortened, the schedules must be con-
sidered on an individual basis for each utility. The variety
of startup problems encountered with large precipitators can
3-4
-------
require more than 6 months to rectify before achieving satis-
factory operation and thus compliance unless an intensive effort
is made by both the utility and precipitator manufacturers.
Sources of Additional Information
Type of
Source Information*
1. Handbook of Emissions, Effluents, and
Control Practices for Stationary
Particulate Pollution Sources P, E,
NTIS No: PB 203-522
2. A Manual of Electrostatic Precipitator
Technology, Part II - Application
Areas • C
NTIS No. PB 196-381
3. Steam, Its Generation and Use
Babcock and Wilcox Company, 1963 P
4. Atmospheric Emissions from Coal
Combustion P, E
PHS Publication No. 999-AP-24
* P = Process description
E = Emission rates
C = Control devices
3-5
-------
Figure 3.1.2 Schedule for installation of an electrostatic precipitator
for particulate pollutant control.
= Milestones
•• = AcKvity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Dote of award of control device contract.
3 Date of initiation of on-s!te construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completedc
5 Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
ELAPSED TIME (WEEKS)
4
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.1.3 Schedule for installation of a wet scrubber for particulate
pollutant control on a coal-fired utility boiler.
CO
I
= Milestones
•• - Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-1
1-H
H-J
J-2
2-K
0lS"
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.1.2 Coal-Fired Industrial Boilers
Process Description - Coal-fired industrial boilers are
generally distinguished from large utility boilers by their
size, coal-firing method, and operating steam pressure.
Capacities of industrial boilers are lower, ranging from 1000
to 500,000 pounds per hour of steam. Pulverized-coal-fired
boilers are used for generating steam loads of 300,000 pounds
per hour or higher. The smaller boilers are often operated
with wide variations in loads, and stoker-fired furnaces are
uniquely suited to this fluctuating demand.
Atmospheric Emissions - Sources of particulate emission from
industrial boilers are identical to those from utility boilers:
the coal receiving and handling operations, the furnace flue
gases, and the ash disposal operations. Fly ash in the flue
gas represents the major particulate emission source. The
quantity emitted depends upon the ash content of the coal,
the method of combustion, and the control equipment used.
Uncontrolled pulverized-coal-fired boilers generally emit about
160 pounds of fly ash for each ton of coal burned. Emissions
from stoker-fired furnaces are about 130 pounds per ton of
coal, but vary widely.
3-8
-------
Control Systems - Electrostatic precipitators have been used
almost exclusively for high-efficiency particulate emission
control. Their use on industrial size boilers has not been
widespread, however; most installations are equipped only with
mechanical collectors, if anything. Electrostatic precipitators
can attain efficiencies of more than 99 percent. In precip-
itator design, particular attention should be given to the
sulfur content of the coal to be burned and the expected operat-
ing precipitator temperature, since both factors affect
collection efficiency.
Some facilities are installing wet scrubbers for fly ash
control because of the possibility of modifying the control
system at a later date for collection of sulfur oxides.
Compliance Schedules - Figures 3.1.4 and 3.1.5 illustrate,
respectively, expeditious schedules for installation of an
electrostatic precipitator and a wet scrubber for fly ash
control. The time required for installation of additional
units on the same site after completion of the first unit can
add 3 months to the schedule. No schedule is shown for SO2
and NO control, since these systems should be studied on an
A.
individual basis.
3-9
-------
Sources of Additional Information
Type of
Source Information*
1. A Manual of Electrostatic Precipitator
Technology, Part II - Application
Areas C
NTIS No. PB-196-381
2. Atmospheric Emissions from Coal
Combustion P, E
PHS Publication No. 999-AP-24
3. Steam, Its Generation and Use P
Babcock and Wilcox Company, 1963
4. Background Information for Proposed
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants, and Sulfuric Acid Plants E, C
NTIS No. PB 202-459
* P = Process description
E = Emission rates
C = Control devices
3-10
-------
Figure 3.1.4 Schedule for installation of an electrostatic precipitator for particulate
pollutant control on coal-fired industrial boiler.
Milestones
• ~ Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed„
5 Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
I-H
H-J
J-2
2-K
ELAPSED TIME (WEEKS)
4
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare prelim'nary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.1.5 Schedule for installation of a wet scrubber for particulate
pollutant control on a coal-fired industrial boiler.
u>
i
= Milestones
• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
8
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.2 Solid Waste Disposal
3.2.1 Municipal Incinerators
Process Description - Capacities of municipal incinerators
range from approximately 50 to 1000 tons of refuse per day.
In the incineration process, as shown in Figure 3.2.1, refuse
is brought to the unloading/charging area. It is then fed to
the incinerator, either in batches or continuously, and the
combustible fraction of the refuse is burned. In multiple
chamber units, air may be added in mixing or secondary chambers
to complete the combustion of the volatile materials driven off
in the primary refuse burning chamber.
The ash residue from the furnace is periodically removed,
quenched, and disposed of, usually in a landfill.
Atmospheric Emissions - Sources of particulate emissions include
combustion gases from the furnace and fugitive dust emissions
from the handling and disposing of ash from furnace and control
device hoppers. Odors can also be a serious problem if proper
housekeeping procedures are not strictly followed. Of these
sources, the furnace combustion gases represent the largest
emission potential. The particulate emission rate is highly
3-13
-------
U)
I
_,
CONT ROL
ODOR. DUST,
LITTER
ODOR OUST
(LITTER 1
t 1
SOLID TIPPING, SOLI!
WASTE STORAGE, WAST
» AND
CHA»EANG
*
SHREC
(OPTIO
GASES
AND
ENTRAINED
SOLIDS
PLANTS WITHOUT |
AIR POLLUTION CONTROL
r
STACK
t
(AUXILIARY
FUEL) AIR AND/OR WATER
AIR
1 ,.
E| | DRYING GASES GAS FLUE GASES ^ Al
"^i I w' AINU ^— v^/V>JU->i l^Jr-* ^ /™/*"\/"M ?Njf
TREATE!
GASES
? POLLUTION
CONTROL
i I iriNiiTinN v-UULitNo DEVirF
DER \^ RESIDUE- FLY ASH
NAL) WATER 1 (WATER)
| ,. •• '
RESIDUE
QUENCHING
(FLY ASH
WATER' , WATER , WATER)
TREATMENT
•• + It
FLY ASH
(WATER)
RESIDUE (V/ATER) EFFLUENT SLUDGE FLY ASH
i i WATER (FLY ASH)
LAND SEWER
DISPOSAL
Figure 3.2.1 Municipal incinerator process
-------
variable, depending upon such factors as furnace design,
operating conditions, and type and characteristics of the refuse.
Particulate emissions from an uncontrolled incinerator typically
range between 8 and 70 pounds per ton of refuse burned.
Control Systems - Many incinerators are designed with a settling
chamber and water spray or baffle as an integral part of the
incinerator system. Although these are considered air pollution
control systems, their collection efficiencies are generally
very low on a weight basis. They do not provide sufficient
control to meet most emission regulations.
Wet scrubbers are the most common high-efficiency air
pollution control devices installed on municipal incinerators.
Scrubber systems should operate with pressure drops between
approximately 10 and 25 inches of water to be effective for
meeting most regulations. Electrostatic precipitators are also
being installed to control emissions. Both these devices are
capable of operating with collection efficiencies as high as
99 percent.
Compliance Schedules - Figures 3.2.2 and 3.2.3, respectively,
illustrate expeditious schedules for installation of a wet
scrubber and an electrostatic precipitator for incinerator
3-:
-------
combustion gases. The schedule for the wet scrubber system
includes the time required for installation of associated
equipment for waste water treatment.
Sources of Additional Information
Type of
Source Information*
1. Systems Study of Air Pollution from
Municipal Incinerators P, E, C
APTD-1283, 1284, 1285
2. A Manual of Electrostatic
Precipitator Technology, Part II-
Application Areas C
NTIS No. PB 196-381
3. Municipal Incineration, A Review
of Literature P, E, C
Publication No. AP-079
4. Air Pollution Aspects of Emission
Sources: Municipal Incineration E, C
Publication No. AP-092
* P = Process description
E = Emission rates
C = Control devices
3-16
-------
Figure 3.2.2 Schedule for installation of a wet scrubber for particulate
pollutant control on a municipal incinerator.
/T\
U)
I
= Vilest-ones
•" = Activity and duration in weeks
MILESTONES
1 Dom of subrTMttai of final control pian to appropriate agency.
2 Date o* award of control device contract.
3 Dcte of iri*iation of on-site construction or installation of emission control equipment.
4 Dafe by *vhich on-slte construction or Installation of emission control equipment is completed.
5 Date by which final compliance Is achieved.
ELAPSED 7!V,E WEEKS)
isi.-nctlon
A-C
A-B
C-D
D-E
E-f
F-G
C-:
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evalv^'e control alternatives
Corpp it funds for total program
Pn :•: :f prelinirary ro^rrol p'un and compliance
sc' •> .ule fos agency
Agency review aid approval
fina' . ;>ion> and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L
L-M
M-N
L-O
O-r
P-Q
Q-3
3-N
N-R
R-4
4-5
Review and approval of assembly drawings
Vendor prepares fabrication drawings
Fabricate contro. aevice
Prepare e-gi'.eering arawings
Pro".re coni*.< .''^>n bids
EvoL^ire co-'s': action n ci
Aw j'J ^ • s' jr.'ion cont- •..f
On-site construction
InstaM contro. device
Complete construcrion (system tie-in)
Startup, shakedown, preliminary soorca test
-------
Figure 3.2.3 Schedule for installation of an electrostatic precipitator for
particulate pollutant control on a municipal incinerator.
CO
i
oc
MILESTONES
]
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-f
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity o-id duration in weeks
Date of submittal of final control plan to appropriate agency.
Dcte of award of control device contract.
Dcte of initiation of on-site construction or installation of emission control equipment.
Dale by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finali7e plans and specifications
Procure cont'oi devic* bids
ivaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
1_-M Vendor prepares fabrication arawings
M-N Fabricate conrrol device
J.-O Prepare engineering drawings
O-P Procure construction bids
p-Q Evaluate construction bids
Q-3 Awa^d construction contract
3-N On~site construction
N-R install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.3 Evaporation Sources
3.3.1 Surface Coating
Process Description - Surface coating operations consist of
applying a coat of paint or varnish to an object, evaporating
the solvent by application of heat, and finally hardening the
coated surface by subjecting it to higher temperatures.
Coating operations vary in size from small manually operated
units to large auto body spraying and dipping operations.
This classification also includes coating and decorating of
cans.
Large-scale solvent evaporation and baking operations are
conducted inside an oven, where the required heat is supplied
by banks of infrared lamps or by direct or indirect combustion
of natural gas or fuel oil. During the surface coating and
drying operation, most of the volatile constituents of the
coated material evaporate and are released to the atmosphere
if air pollution control equipment is not used.
Simplified schematics of surface coating operations, with
direct-fired afterburner and adsorption systems to control
hydrocarbon emissions, are shown in Figures 3.3.1 and 3.3.2.
Freshly coated pieces enter the oven, in which the pressure is
3-19
-------
Ambient
Air
Natural
• Gas
Figure 3.3.1 Surface coating operation with
afterburner control system.
Adsorbent
Vessel
,_
Work
In
1 tvol f
&T r
1 i
1 i
i
1
v- -s
^T^
I
Vent
Gas
Adsorbent
Vessel
Steam
i
j Decanter
__fx^i__r"=—- — ^i ^ r *i Solvent
P<3 i-^i v j
>c
*-ixi — , — cxs-*-* — -H /
,
' .. T ? L
'
Contaminated Steam
1 Oven
VT ;V* \jf ^x ^^ ^s \.s ^/ •*.* vx vx \
vy* \.X x
Condensate
to Stripping
Vent or Drain
/ v^
Work
Out
Fuel or heated air
Figure 3.3.2 Surface coating operation with
adsorption control system.
3-20
-------
maintained slightly below atmospheric conditions to prevent any
leakage of solvent vapors into the room and to draw sufficient
room air into the oven to prevent the formation of explosive
mixtures. Most of the volatile components of the coating are
released shortly after entering the oven. This mixture of hydro-
carbons and air is withdrawn from the oven by means of a blower.
Atmospheric Emissions - Hydrocarbons from the coating application
and drying processes are the primary emissions of concern. Some
particulate emissions also occur from the paint spraying
operations, but these are generally controlled near the point
of application by fiberglass filters and/or a water curtain
built into the booth's exhaust system.
The type and quantity of hydrocarbon emissions vary directly
with the type and quantity of solvent in the coating. The
solvent content often amounts to about 50% of the total weight
of the coating material. Overall process emissions can be
estimated by material balance calculations, since all of the
solvent must evaporate in some part of the process. In direct-
fired ovens, however, some solvent vapor is burned.
Control Systems - Hydrocarbon emissions can be minimized by
using control equipment or by reducing the solvent content of
the coating. The use of "exempt" solvents and water-base
3-21
-------
coatings, and the setting or drying of coatings by application
of other types of energy (eg. infrared, ultraviolet) instead
of heat, are process changes that reduce emissions.
Where process changes cannot be made, control equipment
such as direct-fired afterburners, catalytic afterburners, and
adsorption systems can be used to reduce emissions. Selection
of an air pollution control system depends on several factors
including the value of the recovered solvent and the avail-
ability and cost of fuel oil or natural gas for incineration.
Generally, small operations where the flow rate of vented gas
is less than 5000 SCFM use direct-fired afterburners without
heat recovery. Large operations with emissions in the tens of
thousands of SCFM use direct-flame incineration with heat
recovery, or catalytic burners. When the solvent is worth
recovering, an adsorption system may be incorporated into the
process.
Compliance Schedule - Figures 3.3.3 and 3.3.4 illustrate
expeditious schedules for installation of a field-erected
adsorbtion system and a skid-mounted "package" adsorption
system, respectively. The type of system used depends upon
such factors as nature of the recovered solvent and volume of
vented gas. Figure 3.3.5 represents an expeditious schedule
for installation of an afterburner.
3-22
-------
Sources of Additional Information
Type of
Source Information*
1. Air Pollution Engineering Manual P, E, C
NTIS No: PB 190 243
2. Afterburner System Study Prepared by
Shell Development Company for EPA
under Contract EHSD 71-3 C
Office of Air Programs, Research
Triangle Park, North Carolina
3. Evaluations of Emissions and Control
Technologies in the Graphic Arts
Industries P, E, C
NTIS No. PB 195-77C
* P = Process description
E = Emission rates
C = Control devices
3-23
-------
Figure 3.3.3 Schedule for installation of field-erected absorption
system including distillation unit on a surface coating operation
for hydrocarbon emissions control,
u>
i
to
.£>
~ Milestones
*" ~ Activity and duration in weeks
MILESTONES
1 Date of submitted of final control plan to appropriate agency 0
2 Dafe of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment0
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
ELAPSFD TIME (WEEKS)
\2
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure crv trol device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepores fabrication drawings
M -N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.3.4 Schedule for installation of a packaged adsorption system including
field-erected distillation unit on a surface coating operation
for livarocarbcm e* \iT.~ ions control.
I
M
MILESTONES
?
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
F-C
G-l
1-H
H-J
J-?
2-K
Milestones
Activity and duration in weeks
Date of sobmittal of final control plan to appropiic-lt agency*
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of pmission control equipment is completed*
Date by which final compliance is achieved8
1IMF (WEEKSj
Preliminary investigation
Source tests
Evaluate control altcinatives
Commit funds for total program
Prepare preliminaiy control plan ^nd compliance
schedule for agency
Agency review ano Approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabi icate con*ro' device
L-O Prepare engineering drawings
O-P Procure construction bids
p-Q Lvaluate c,>ii*rri'Cffv bun
Q-3 Award constructor, contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, s r-kedown, preliminary source test
-------
Figure 3.3.5 Schedule for installation of an afterburner
on a surface coating operation for hydrocarbon emissions control.
to
- Milestones
*• = Activity and duration in weeks
MILESTONES
1 Date of sobmittal of final control plan to appropriate agency.
2 Date of award of control device contract,
3 Date of initiation of ort-site construction or installation of emission control equipment.
4 Date by which on-sire construction or installation of emission control equipment is completed,
5 Date fay which final compliance is achieved.
ELAPSED TIV.E (WH5KS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
f-G
G-1
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drc../.,",aS
l_-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source lest
-------
3.3.2 Petroleum Storage
Process Description - Storage vessels can be classified as
either closed-storage or open-storage tanks. Pressure vessels
used for storage of volatile hydrocarbons are most commonly
cylinders, spheres, or spheroids. Closed vessels for less
volatile fractions are normally fixed-roof tanks, floating-
roof tanks, or conservation tanks. Normally fixed-roof tanks
or lifted-roof conservation tanks are used for low volatility
liquids. Floating-roof tanks and diaphragm conservation tanks
minimize the vapor space and are normally used for volatile
fractions or for hydrocarbons that present potential hazards
for fire or explosion.
Open-storage vessels, found in a variety of shapes, are
now used infrequently because of safety and product conser-
vation considerations.
Atmospheric Emissions - Hydrocarbon vapors are emitted as a
result of volatilization of the stored material. Since
cylindrical flat-roof tanks operate at only a very slight
positive pressure, the diurnal atmospheric temperature changes
cause expansion and contraction of the tank vapor space, and
hence emissions or "breathing". Emissions are particularly
significant in fixed-roof tanks since filling also causes
breathing.
3-27
-------
Control Systems - Effective control methods include the use
of floating roofs, reducing either the exposed surface area
or the tank volume with devices such as plastic blankets and
spheres, and vapor recovery systems. Installation of an
internal floating roof is the most commonly used control
technique for existing tankage.
Compliance Schedules - Figure 3.3.6 represents an expeditious
schedule for installation of a floating-roof with a double
deck on a existing storage tank.
Sources of Additional Information
Type of
Source Information*
1. Air Pollution Engineering Manual P, E, C
PHS Publication No. 999 AP-40
2. Petroleum Refinery Engineering P, C
W.L. Nelson, McGraw-Hill, 1958
3. Atmospheric Emissions from Petroleum
Refineries - A Guide for Measurement
and Control E
NTIS No. PB 198-096
* P = Process description
E = Emission rates
C = Control devices
3-28
-------
Figure 3.3.6 Schedule for installation of an internal floater
on an existing storage tank for hydrocarbon emissions control*.
NJ
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2-3
3-4
4 -5
ELAPSED TIME (WEEKS)
Date of submitta! of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to sife .
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
~V
1
. it
*Note: For tanks 150 to 200 ft. in diameter,
add 10 weeks to Steps 3-4.
-------
3 . 4 Chemical Processes
3.4.1 Nitric Acid
Process Description - All nitric acid produced commercially
is manufactured by the ammonia oxidation process. Despite
many variations in operating details among the plants producing
nitric acid, three basic steps are common to all: (1) oxidatioi
of ammonia to nitric oxide, followed by (2) oxidation of nitric
oxide to the dioxide, and finally (3) absorption of nitrogen
dioxide in water to produce nitric acid with the release of
additional nitric oxide.
A scheratic flow diagram for production of nitric acid
by the ammonia oxidation pressure process is shown in Figure
3.4.1. In this process ammonia vapors are mixed with preheated
compressed air and are passed over a platinum catalyst to form
nitrogen oxide and water. The heat content of the gas, pri-
marily due to the exothermic reaction, is recovered by pre-
heating the absorber tail gases and the process air, and
finally by passing the gas through a waste heat boiler to
generate steam. The gases are then filtered to recover the
valuable platinum catalyst dust and further cooled in a water
cooler. The successive oxidations and hydrations of the nitric
oxide are conducted with continuous water cooling in a stair-
less steel absorption tower.
3-30
-------
COMPRFSS.W (XI'ANDIK
PROO'T.t 5565%
HNO,
Figure 3.4.1 Flow diagram of nitric acid manufacture
by the pressure process, with catalytic
tail gas control system.
The tail gas leaving the absorption tower normally
contains 0.2 to 0.3 percent nitrogen oxides by volume. In
an uncontrolled plant these gases are vented, after passing
through an expander turbine for energy recovery.
Atmospheric Emissions - Emissions of nitrogen oxides from
nitric acid plants are estimated to be about 43 pounds per ton
of acid produced. This corresponds to about 3000 ppm NO
^C
(by volume) in the exit gas stream. Nitrogen dioxide, dis-
tinguished by its opaque reddish-brown color, makes up approxi-
mately 50 percent of this emission. The remainder of the gas
is the colorless nitric oxide compound.
3-31
-------
Control Systems - Equipment for nitrogen oxides control
includes catalytic reduction, molecular sieve adsorption
systems, and caustic scrubbers. Catalytic reduction can
reduce emissions by 36 to 99 percent (80 percent average)
depending on design, fuel input, and operating teriperatures.
The ir.oleculi.ir sieve sy.stem provides efficiency of over 99
peicent/ buu has only recently been applied to full-size
systems. Custic scrubbers are used only under special
circumstance; (e.g. where there is a market for recovered
byproducts).
Compliance Schedules - Figures 3.4.2 and 3.4.3 illustrate,
resoectively/ expeditious schedules for installations of catal^
reduction unit with heat recovery and molecular sieve adsorptic
system. At present, molecular sieve systems are being installs
on two nitric acid plants. Because no nitric acid plant is
operating with molecular sieves, the schedule is tentative.
Sources of Additional Information
Type of
Source Information*
1. Kirk-Othmer's Encyclopedia of Chemical
Technology, Volume 13, 2nd edition P
2. i-'tr. ospheric Emissions from Nitric Acid
Manufacturing Processes.
PHS Publication No. 999-AP-27 e. E,
-------
3. Background Information for Proposed
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants, and Sulfuric Acid Plants E, C
NTIS No. PB 202-459
4. Air Pollution Aspects of Emission
Sources: Nitric Acid Manufacturing E, C
Publication No. AP-093
* P = Process description
E = Emission rates
C = Control system
3-33
-------
Figure 3.4.2 Schedule for installation of a catalytic reduction
unit with waste heat recovery on a nitric acid plant
for nitrogen oxide emissions control.
co
I
MILLSTONES
ACTIVITIES
Designotion
A-C
A-B
C-D
D-E
t-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
A ,j\>y and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-sire construction or installation if emission control equipment is completed
Date by which final compliance is achieved.
D TIME (WEfKSj
56
60
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule ror agency
Agency review and approval
Finalize plans and specifications
Procure <-o TIO! device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site con;tructio~
N-R Install contra! device
R-4 Complete construction (system tie-in)
4-5 startup, shakedown, preliminary source test
-------
Figure 3.4.3 Tentative schedule for installation of molecular
sieve adsorption system of a nitric acid plant
for nitrogen oxide emissions control.
i
/
31.
^
U)
I
Ul
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3-4
4 -5
ELAPSED TIME (WEEKS)
Dafe of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contact.
Equipment fabrication and delivery of structural components *o site.
Delivety of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-------
3.4.2 Phosphoric Acid
Process Description - Phosphoric acid is produced by two basic
methods, the wet process and the thermal process. In the wet
process, phosphate rock is treated with sulfuric acid, The
ensuing chemical reactions result in the formation of phosphoric
acid and the precipitation of calcium sulfate. The latter is
filtered off, and the acid is concentrated from about 32 percent
P2°5 to about 54 percent P20 . A simplified flow diagram is
shown in Figure 3.4.4.
CVPSMM $LURffr
TO POMO
Figure 3.4.4 Wet-process phosphoric acid plant.
3-36
-------
In the thermal process, phosphoric acid is produced from
elemented phosphorous. Three basic steps are involved:
(1) burning the molten phosphorus in a suitable chamber to
produce phosphorus partoxide; (2) hydrating the phosphoric acid
and mist; (3) removal of the phosphoric acid mist from the gas
stream. A simplified flow diagram of the major steps in the
manufacture of phosphoric acid by the thermal process is shown
in Figure 3.4.5.
i STACK
I EFFLUENT
(AIR + H3P04 MIST)
ACID TREATING PLANT
STACK EFFLUENT
(AIR t H?S)
HYDROGEN SIJLFIOE,
SODIUM HVOROSIILFIDE,
OR SODIUM SULFIDE
FILTER
PRODUCT
PHOSPHORUS
COMBUSTION
CHAMBER
HYDRA"! OR-
ABSORBER COOLING WATER
BURNING AND HYDRATION SECTION
ACID TO
STORAGE
BLOWER PUMP
ACID TREATING SECTION
(USED IN THE MANUFACTURE OF ACID
FOR FOOD AND SPECIAL USES)
Figure 3.4.5 Thermal-process phosphoric acid plant
Atmospheric Emissions - The emissions of most concern in the wet
process are the fluorine compounds liberated from the rock by the
sulfuric acid. These consist of hydrogen fluoride, silicon tetra-
fluoride and some products of reaction and decomposition of the
3-37
-------
latter. Most phosphate rock contains 3.5 to 4 percent fluorine,
and half of this may be volatilized in the processing. Fluorides
may be emitted from exposed surfaces of reaction slurry, from
aqueous solutions of fluorine compounds, and from any evapora-
tion process.
The major atmospheric contaminant from tne thermal process
is phosphoric acid mist discharged in the absorber exit gas.
This gas stream also contains water vapor and trace amounts of
nitrogen oxides. Another important emission is the discharge
gas from the acid-treating tank. These emissions are intermitten-
and range from 10 to 2500 parts per million of hydrogen sulfide.
Control Systems - Because the principal atmospheric contaminants
generated in the wet process are gaseous fluorides, scrubbing is
universally employed to control emissions. Devices used for
control include venturi scrubbers, impingement scrubbers, and
various kinds of spray towers.
For the thermal process, primary control devices for control
of emissions of acid mist include high-pressure wire-mesh elimi-
nators and high-efficiency glass-fiber mist eliminators.
Compliance Schedules - Figure 3.4.6 illustrates an expeditious
schedule for installing a wet scrubber system on either a wet or
thermal process plant. An expeditious schedule for installation
of a high-efficiency mist eliminator is shown in Figure 3.4.7.
3-38
-------
Figure 3.4.6 Schedule for installation of wet scrubber system
on phosphoric acid manufacturing operation
for gaseous and particulate fluoride control.
- Milestones
•• = Activity and duration in weeks
MILESTONES
1 i_Ajte of submittal of final control plan to appropriate agency °
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
'"LAPSED TIME (WEEKS)
ACTIVITIES
F-G
G-l
1-H
H-J
J-?
74
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure cont'ol device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.4.V Schedule for installation of high-pressure mist eliminator
on phosphoric acid manufacturing operation for acid mist emissions control
i
*-
o
MILESTONE
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
2-3
3-4
4 -5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site .
Delivery of remaining equipment and completion of construction including process tie in,
Equipment start up and source testing .
ELAPSED TIME (WEEKS)
IQ
-------
Sources of Additional Information
Source
Type of Information*
1) Atmospheric Emissions from
Wet-Process Phosphoric Acid
Manufacture.
NAPCA Publication No. AP-57
2) Atmospheric Emissions from
Thermal-Process Phosphoric
Acid Manufacture.
NAPCA Publication No. AP-48
P,E,C
P,E,C
* P = Process
E = Emissions
C = Control devices
3-41
-------
3.4.3 SuIfuric Acid
Process Description - Essentially all sulfuric acid is produced
by the contact process shown schematically in Figure 3.4.8 for
a sulfur burning plant. Sulfur or sulfur-containing raw materi-
als (e.g. spent acid) are burned to form SO-, which is then
£
catalytically oxidized in a converter to SO... The heat liberated
in the converter reaction is removed in several stages by inter-
mediate gas cooling. The exit gas from the converter is cooled
and the S03 is absorbed in a circulating stream of 98 percent
H2S04.
IMAM DIUM f**&-
Ow DOWN ^—— —'
fUlHACI I 01 it • »0il! • CONVftMt
<> f fl O 0 W C t
Figure 3.4.8 Contact-process sulfuric acid plant burning
elemental sulfur .
3-42
-------
Variations in the contact process are due primarily to
differences in the sulfur feedstock. Units operating with spent
acid, sludge, or tail gas are more complicated than sulfur-
burning plants since these are contaminated streams. After
burning the feed stream in these "wet gas" plants, the resulting
gas stream requires cleaning and cooling to remove dust, acid
mist, gaseous impurities, and excessive water vapor. Following
gas drying, the process is essentially the same as in an ele-
mental sulfur-burning plant.
Atmospheric Emissions - S02 emissions vary inversely with the
S0~ to SO., conversion efficiency. For older sulfur-burning
plants with three-stage converters, conversion efficiencies are
typically 95 to 96 percent, which correspond to emissions of
55 to 70 pounds of S02 per ton of acid produced. Conversion
efficiencies for four-stage converters range from 96 to 98
percent, with S00 emissions between 26 and 55 pounds per ton.
^4
Dual absorption plants, discussed under Control Systems, can
achieve conversion efficiencies in excess of 99 percent; the
resulting SO,, emissions usually range between 2 and 7 pounds per
ton of acid.
Acid mist emissions are also significant, especially for
plants producing oleum or using sulfur feed stocks other than
elemental sulfur. If uncontrolled, emissions range between
3-43
-------
0.5 and 5 pounds per ton of acid produced at sulfur-burning
plants, and about 1 to 10 pounds per ton at spent acid plants.
Control Systems - S02 emissions can be controlled by use of a
dual absorption process, sodium sulfite scrubbing, ammonia
solution scrubbing, or molecular sieves. In the dual absorp-
tion process, SO- emissions are decreased by increasing the S0~
to SO- conversion efficiency. The S03 formed in the initial
converter stages is removed in a primary absorber, and the
remainder of the gas is returned to the converter. The addi-
tional SO., formed is absorbed in a secondary absorber. The dual
absorption configuration can reduce SO,, emissions to between
approximately 2.0 and 7 pounds per ton of acid produced.
Sodium sulfite scrubbing of absorber off-gas can reduce SO2
emissions to between 2.0 and 3.0 pounds per ton. The recovered
SO- is normally recycled to the acid plant. Ammonia solution
scrubbing can reduce SO- emissions to approximately 100 ppm.
^
Spent scrubbing liquor is either used to produce ammonium sulfate
or thermally decomposed to recycle SO- to the acid plant. A
multi-stage scrubber and a high-efficiency particulate collection
device are normally required to minimize ammonia losses and to
prevent a visible plume caused by ammonium salts.
Molecular sieve separation is capable of reducing SO-
emissions to between 50 and 100 ppm. The recovered SO- is
recycled to the acid plant.
3-44
-------
Acid mist emissions are usually controlled by use of
electrostatic precipitators or mist eliminators. Mist elimi-
nators are generally preferred because of their higher collection
efficiency and hence their ability to operate with zero visible
discharge.
Compliance Schedules - Figure 3.4.9 illustrates an expeditious
schedule for modifying an existing plant to use the dual absorp-
tion process. Figures 3.4.10 and 3.4.11 illustrate expeditious
schedules for installation of sodium sulfite and ammonium
solution scrubbing processes, respectively; the schedule for the
ammonium solution scrubbing process incorporates the time required
for simultaneous installation of a high-efficiency particulate
control device. An approximate time schedule for installation
of a molecular sieve separation process is shown in Figure 3.4.12.
Since this process has only recently started in commercial opera-
tion, this schedule is tentative.
Figure 3.4.13 illustrates an expeditious schedule for instal-
lation of a mist eliminator for controlling acid mist emissions.
3-45
-------
Sources of Additional Information
Source Type of
Information*
1) Engineering Analysis of Emissions P, E, C
Control Technology for Sulfuric
Acid Manufacturing Processes
NTIS No. PB 190-393
2) Background Information for Proposed P/ E, C
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants, and Sulfuric Acid Plants
NTIS No. PB 202-459
3) Atmospheric Emissions from Sulfuric P, E, C
Acid Manufacturing Processes
PHS Publication No. 999-AP-13
4) Duecker, W. W. and J. J. West, P
Manufacture of Sulfuric Acid
A.C.S. Mono. 144, Reinhold Pub. Co.,
New York, N. Y., 1959
5) Air Pollution Aspects of Emission E, C
Sources: Sulfuric Acid Manufacturing
NTIS No. 200-079
* P = Process description
E = Emission rates
C = Control devices
3-46
-------
Figure 3.4.9 Schedule for modifying an existing sulfuric
acid plant to the dual absorption process
for sulfur oxides emission control.
-E
00
i
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
-------
Figure 3.4.10 Schedule for installation of a
sodium sulfite scrubbing system
for sulfur oxides emission control.
£3
lls
co
co
MILESTONES
1
2
3
4
5
ACTIVITIES •
DESIGNATIONS
1 -2
2-3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-------
Figure 3.4.11 Schedule for installation of an ammonia scrubbing system,
including mist eliminator, on a sulfuric acid plant
for sulfur oxides emission control.
•s
U)
I
tt*
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3-4
4 -5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved .
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
-------
Figure 3.4.12 Tentative schedule for installation of a molecular
sieve separation process on a sulfuric acid plant
for sulfur oxides emission control.
/
J
4
5
I
Ul
o
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment,
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
fquipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
£,(*
-------
Figure 3.4.13 Schedule for installation of a mist eliminator
on a sulfuric acid plant for acid mist
emission control.
1
j£>
2
ite FT
LL
s.
w>
4
,x, •
5
oo
I
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
Dote of submitfal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
-JL.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
52 weeks if booster blower required.
-------
3.4.4 Paint and Varni sh
Process Description - The manufacture of paint involves dispers-
ing a colored oil or pigment into a vehicle, usually a resin or
oil, and adding either a hydrocarbon solvent or water to lower
the viscosity of the paint for ease of application. Only
physical processes are involved; no chemical reactions take place.
The manufacture of varnish also involves the mixing and
blending of various ingredients. In this process, however,
chemical reactions are initiated by cooking the varnish in open
or closed gas-fired kettles for 4 to 16 hours at temperatures
between 200 and 650°F.
Atmospheric Emissions - Particulates can be emitted from the
handling of dry pigments. The quantity emitted varies with the
care taken in handling and with the method of transferring the
dry material. Typical emission values range from 0.5 to 1.0
percent of the pigment handled.
Emissions of hydrocarbons, the pollutants of primary concern,
are due to the use of organic solvents. Depending on the cooking
time and temperature, type of solvent, and type of enclosure,
hydrocarbon emissions from varnish cooking range from 20 to 160
pounds per ton of product. The corresponding hydrocarbon emission
rate tor paint 'i^"oifacture is approximately 30 pounds per ton of
paint produced.
3-52
-------
Control Systems - Catalytic oxidation and direct-flame incinera-
tion are used to control hydrocarbon emissions from paint and
varnish plants. With catalytic units, the collected process off-
gases and vapors are heated by combustion of fuel to approximately
600 to 800°F. They are then passed through the catalyst bed,
where oxidation of the hydrocarbons further increases the tempera-
ture. In thermal incineration units, the temperature is raised
to 1200° to 1500°F for residence times between 0.25 and 0.5
second. In both types of units, the hydrocarbons are oxidized
to CO2 and water vapor.
Compliance Schedules - Figure 3.4.14 illustrates an expeditious
schedule for installation of an afterburner.
Sources of Additional Information
Type of
Source Information*
1) Encyclopedia of Chemical Technology P,C
Kirk-Othmer's Vol. 14, 2nd Edition
2) Exhaust Gases from Combustion and E
Industrial Processes
NTIS Publication PB 204-861
3) Air Pollution Engineering Manual P,E,C
PHS Publication No. 999-AP-40
* P = Process description
E = Emission rates
C = Control devices
3-53
-------
Figure 3.4.14 Schedule for installation of an afterburner on
paint or varnish operations for hydrocarbon emissions control.
u>
i
Ln
= Milestones
•- = Activity and duration in weeks
MILESTONES
1 Date of submirtal of final control plan to appropriate agency*
2 Date of award of control device contract.
3 Date of initiation of on-sife construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ACTIVITIES
Designotion
A-C
A-B
C-D
D-E
E-F
F-G
G-l
I-H
H-J
J-2
2-K
ELAPSED TIME (WEEKS)
2,
2. (o
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K>L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.4.5 Soap and Detergents
Process Description - Present commercial methods for the
manufacture of soap consist primarily of catalytic hydrolysis
of various fatty acids with sodium or potassium hydroxide to
form a glycerol-soap mixture. This mixture undergoes
separation through distillation, followed by neutralization
and blending to produce different grades of soap. Soap is
finished in many forms, such as bars, flakes, granules,
liquids, and powder.
In the manufacture of soap in powder form, the material
is spray dried. Prior to spray drying, additives to complete
the formulation are suspended or dissolved in the hot soap
and the mixture is then pumped through nozzles near the top
of a spray tower. Hot air circulated through the tower
evaporates water from the spray, forming the powdered soap.
A schematic flow diagram for the manufacture of soap is shown
in Figure 3.4.15. CONTROL DEVICE
FATTY ACIDS , VACUUM
CATALYST "'DROL.ZER smL
(NaOH or KOH)
1 1
CRUDE GLYCERINE BOTTOMS
TO RECOVERY
CAUSTIC SODA
SPRAY
DRYER
1
POWDER
" BARS
CHiPS
FLAKES
. LIQUID
Figure 3.4.15 Soap manufacture.
3-55
-------
In the manufacture of synthetic detergents, fatty alcohols
or linear alkylate compounds are first treated with sulfuric
acid. The sulfonated compounds are then neutralized with
caustic solution, and various dyes, perfumes, and other
compounds are added. The resulting paste or slurry is pumped
to the top of a drying tower and sprayed through nozzles to
form small droplets. As the droplets descend, the moisture
content is reduced by the countercurrent hot air flow. The
dried detergent is then cooled and packaged. A simplified
flow diagram for the manufacture of detergent granules is
shown in Figure 3.4.16.
EXIT GASES
I SECONDARY
j PARTICULATE
I COLLECTOR
I
AUYLBENZENE
I 1
OLEUM
OLEUM-
FATTY
ALCOHOLS
BUILDERS &
ADDITIVES
CYCLONE
FINES TO PROCESS
HEATEXCHANGERS
niTTTTTTT
SEPARATOR
SPRAY
DRYER
SECONDARY
COLLECTOR
•FINES RETURNED
TO PROCESS
-HEATED AIR
DRY PRODUCT STREAM
I PRODUCT
& PACKAGING
AIR CONVEYOR
HIGH PRESSURE
PUMP
Figure 3.4.16 Detergent manufacture .
3-56
-------
Atmospheric Emissions - Odors are the emissions of primary
concern from soap manufacture. The severity of odorous
emissions depends upon the type of feed material used. Low-
grade stocks obtained from rendered grease and fats tend to be
odoriferous. Local dust emissions can also occur during
blending, mixing, and packaging of the finished soap. Spray
dryers, if uncontrolled, can be a major source of particulate
emissions.
Emissions from synthetic detergent manufacture can be
classified as those resulting from the preparation of the
synthetic feed compounds from petrochemical stock and those
resulting from the final detergent-making operation. The
former are essentially hydrocarbons emitted from relief
valves, from storage vessels, and from atmospheric and vacuum
fractionation operations. The latter come primarily from the
spray drier. Uncontrolled particulate emissions from the
spray drier are approximately 90 pounds per ton of product.
Particulates can also be emitted from various handling and
packaging operations, although these are usually controlled
because of the product's value.
Control Systems - Particulate and odor emissions from the
spray drying of soap or detergent are commonly controlled by
3-57
-------
a wet scrubber followed by an electrostatic precipitator, if
necessary. The stack gases are sometimes reheated to eliminate
what otherwise would be a visible plume.
Dust from blending, mixing, and packaging operations can
be controlled by collection in a fabric filter. Hydrocarbon
emissions from relief valves and fractionation towers can be
controlled by incineration.
Compliance Schedules - Figures 3.4.17 and 3.4.18 illustrate,
respectively, expeditious schedules for installation of a wet
scrubber/electrostatic precipitator system on a spray drying
tower and a fabric filter on blending and packaging operations.
Sources of Additional Information
Type of
Source Information*
1. Air Pollution Engineering Manual P, E, C
PHS Publication No. 999-AP-40
2. Kirk Othmer's Encyclopedia of
Chemical Technology P
2nd Edition, Volume 18
* P = Process description
E = Emission rates
C = Control devices
3-58
-------
Figure 3.4.17 Schedule for installation of a wet scrubber/electrostatic
precipitator on a spray drying tower for particulate pollutant control.
OJ
I
Ul
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract .
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
-*C-
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
/I fa
-------
Figure 3.4.18 Schedule for installation of fabric filter on blending
and packaging operations for particulate pollutant control.
LO
I
= Milestones
•• = Activity ond duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
55
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.5 Agricultural Products
3.5.1 Grain Handling and Processing
Process Description - Grain handling and processing encompass
a variety of operations from the initial receipt of the grain
at either a country or terminal elevator to the delivery of
such finished products as flour, livestock feed, soybean oil,
and corn syrup. Primary operations in this industry include:
(1) grain handling and transferring; (2) milling of dry corn,
wet corn, soybeans, rice, durum and wheat; and (3) feed
manufacturing.
Grain is handled and transferred at country and terminal
elevators. Country elevators receive grain from farms by
truck for future delivery to terminal elevators. At a typical
terminal elevator, the grain is unloaded, cleaned, dried,
stored, turned periodically, and eventually either shipped to
another elevator or processed at an adjacent facility. Figure
3.5.1 illustrates the basic operations of a terminal elevator.
Milling of dry and wet corn, soybeans, rice, durum, and
wheat involves several steps: (1) grain receiving; (2)
cleaning and drying; (3) grinding or milling; (4) sifting,
separating, and mixing; and (5) final load-out of the finished
products and byproducts. Unloading and loading operations
3-61
-------
IEG VENTS
CJL)
I
NJ
GONDOLA SHIPPING
SPQlfT
GONDOLA & CAR
RECEIVING &
SHIPPING
LEG VENT
GARNER
SCALE
GARNER & SCALE
VENT
SHIPPING CONVEYOR
SHIPPING SPOUT
CAR RECEIVING CONVEYOR •
^CAR REC'G & SHIPPING LEG
I (MISSION POINT
Figure 3.5.1 Terminal elevator.
-------
are similar to those of a terminal elevator. The by-products
of the milling industries are frequently shipped to feed mills
for further processing. Figures 3.5.2, 3.5.3, and 3.5.4
illustrate general operations for soybean processing, flour
milling, and wet corn milling.
Processing of grains into mixed feed involves grinding
the grain, mixing it with the other ingredients required by
the formula, and then forming the feed into the desired shape
and consistency. The basic forms of finished feed are mash,
pellets, and crumbles.
Grinding and mixing are the two basic operations in each
feed mill. Extrusion and cooling are additional operations
in the manufacture of pellets. If pellets are broken into
"crumbles" or "granules", the crumbling operation and screening
follow the pelletizing operation. Figure 3.5.5 illustrates the
general flow diagram for a typical feed mill.
Atmospheric Emissions - Particulate emissions are of primary
concern in most grain industry operations. The emission
rates are highly variable, depending upon such factors as
cleanliness of grain, process design, and operating practices.
Emissions from the various processes generally range between
2 and 8 pounds of particulate per ton of material handled or
3-63
-------
^CONVEYOR
(DIRECTION OF FLOW)
— TOASTER
FLOUR
EDIBLE
PROCESS
PROTEIN
EXTRACTION
ISOLATED
PROTEIN
PROTEIN
CONC.
SUGARS
® '
1 FEED 1
® EMISSION POINT
Figure 3.5.2 Soybean processing,
3-64
-------
®
ELEVATOR
1
PRODUCT CONTROL
r l
SEPARATOR
f l
ASPIRATOR
f J
r
DISC SEPARATOR
. 1
SCOURER
j
® EMISSION POINT
*
MAGNETIC SEPARATOR
1
WASMER-STONER
1
TEMPERING
. 1
TEMPERING BINS
^gJ^mFNrHMfi **5Jr=^
C'
ENTOLETER
. i
GRINDING BIN
. 1
FIRST BREAK
*
r
r
<
«
SIFTER
'
FLOUR
SIFTER
1
ENRICHING
»
t
PACKER BULK DELIVERY
®
-^ RAIL
Figure 3.5.3 Flour milling,
3-65
-------
|; .'f SHELLED'CORN j
STEEPWATER
1
STEEPWATER
EVAPORATORS
t
1. .StEEPWATER J
' '.^CONCENTRATE: ]
f
l
. . : STEEPWATER :
.::':' CONCENTRATE ' HULL (BRAN)
. . : FOR SHIPMENT ,
GLUTEN
f '
1 FEED DRIERS 1 ZEJN j
t »
:CORN''GLUTEN''FE|P j CQRN GLUTEN MEAL
®
t— STARCH DRIERS — i
1
\ t ®
1 .DRY STARCHES. '•' 1 DEXTRIN ROASTERS
t
f DEXTRINS j
[ . CORN SYRUP
p-77"3 PRODUCTS AND INTERMEDIATE POINTS
FIRST CORN CLEANERS
t <«
STORAGE BINS
t s
SECOND CORN
CLEANERS
t @
t
DEGERMINATpRS
f
GERM SEPARATORS
fe t
GRINDING MILLS
t
t
CENTRIFUGAL
SEPARATORS
STARCH WASHING
FILTERS
t
: .. LSTARCH ' ' ''•'
SYRUP AND SUGAR
ENZYME OR
ACID CONVERTERS
t
DECOLORIZING AND
EVAPORATING
®
DRUM OR SPRAY
DRIERS
f
CORN SYRUP.
SOLIDS
GERM WASHING AND 6ft YIN cl
OF GERMS I
1
CRUDE OIL O.L EXTRACTORS (^
i
*
CENTRIFUGAL , "SOAP STOcV" \
•SEPARATORS -... .'i^-. \
t
BLEACHING AND"
WINTERIZING
t
DEODORIZERS L; !l^f^°ERM-' "•
t
J
REFINEb'CORN.OlL . :
t
SUGAR
CRYSTALLIZERS
t
CENTRIFUGALS I * f , ^v^p^OL ._.. . . ., I
*
I •' • DEXTROSE ' -: — p-| LACTIC ACID j
•1 jSORBITOL.
\
— MANNITOL
H^. -METHYL
:GLUCOSIDE
EMISSION POINT
Figure 3.5.4 Wet corn milling.
3-66
-------
i EMISSION POINT
SHIPPING
Figure 3.5.5 Feed manufacturing.
processed. Fugitive dust emissions can be a major problem
in grain unloading or loading. Adequate enclosures and hood-
ing systems must be used in conjunction with emission control
devices.
Control Systems - Fabric filters and mechanical collectors
(cyclones) are the most commonly used control devices.
Fabric filters operate with efficiencies greater than 99.9
percent, with no visible emissions. Air-to-cloth ratios
2
generally range between 10 and 15 (CFM per ft of filter area);
the higher ratios are used for intermittent operations and in
3-67
-------
drier geographical areas. Fabric filters are not used on
streams having high moisture content because of the tendency
of the fabric to "blind".
Because of the relatively large size of the emitted
particulates, mechanical collectors can operate with high
collection efficiencies. For example, cyclones on pneumatic
conveying systems can operate with efficiencies in excess of
99 percent. For most emission sources, however, mechanical
collectors will allow a visible discharge even though
collection efficiencies are relatively high.
Because of the large volumes of effluent and its high
moisture content, and the seasonal nature of grain drying,
grain driers are usually controlled with various types of
relatively low-cost "screen systems". Wire mesh screens,
usually of 24, 35, or 50 mesh, and occasionally 100 mesh,
Dacron have been used. Velocities through the screen are
generally a few hundred fpm. One of the more effective
devices is a sliding-bar, self-cleaning screen system using
100 mesh Dacron. Drier emissions are vented through screens
mounted on long vertical panels in a housing attached to the
drier exhaust. The screens are cleaned by a vacuum head,
which traverses the screen surface. The vacuum stream, which
is about 10 percent of the total drier discharge, is exhausted
through a high-efficiency cyclone or recycled through the
drier.
3-68
-------
Compliance Schedules - Figures 3.5.6 and 3.5.7 illustrate
expeditious schedules for installation of a baghouse or self-
cleaning screen, and a high-energy cyclone, respectively.
Sources of Additional Information
Type of
Source Information*
1. Engineering and Cost Study of Emission
Control in the Grain and Feed Industry. P, E, C
Prepared by Midwest Research Institute
and PEDCo-Environmental under Contract
No. 68-02-0213. Environmental
Protection Agency, Research Triangle
Park, North Carolina
2. Air Pollution Engineering Manual P, E, C
PHS Publication No. 999-AP—40
* P = Process description
E = Emission rates
C = Control devices
3-69
-------
Figure 3.5.6 Schedule for installation of baghouse or self-cleaning screen
filter on grain handling and processing sources for particulate pollutant control,
LJ
I
n
MILESTONES
I
2
3
4
5
ACTIVITIES
Milestones
Activity and duration in weeks
Date of submittol of final control plan to appropriate agency>
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed *
Date by which final compliance is achieved»
ELAPSED TIME (WEEKS)
37
Designation
A-C Preliminary investigation
A-B Source tests
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare preliminary control plan and compliance
schedule for agency
F-G Agency review and approval
G-1 Finalize plans and specifications
1 -H Procure control device bids
H-J Evaluate control device bids
j-2 Award control device contract
2-K Vendor prepares assembly drawings
Review and approval of assembly drawings
Vendor prepares fabrication drawings
Fabricate control device
Prepare engineering drawings
Procure construction bids
Evaluate construction bids
Award construction contract
On-site construction
Install control device
Complete construction (system tie-in)
Startup, shakedown, preliminary source t*s*
-------
Figure 3.5.7 Schedule for installation of high-energy cyclone on
grain handling and processing sources for particulate pollutant control
U)
i
= Milestones
•• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency,
2 Date of award of control device contract.
3 Date of initiation of on-sife construction or installation of emission control equipment,
4 Date by which on-site construction or installation of emission control equipment is completed e
5 Date by which final compliance is achieved,
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
ELAPSED TIME (WEEKS)
2
25
3^
38
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.5.2 Phosphate Fertilizer
Process Description - Among the commonly produced phosphate
fertilizers are normal superphosphate, triple superphopshate,
and ammonium phosphates. Normal superphosphate is produced
by reacting sulfuric acid with phosphate rock. Sulfuric acid
and phosphate rock are intimately mixed, dropped into a den,
held for sufficient time to allow the slurry mixture to set,
and then stored to permit the acidulation to go to completion.
Following the curing period, the solid fertilizer is either
sold as run-of-pile (ROP) product or processed further through
(1) grinding and bagging or (2) granulating and reacting with
ammonia to produce a granular mixed fertilizer. Figure 3.5.8
is a simplified flow diagram of a normal superphosphate plant.
EXIT (GASEOUS FLUORIDE.PARTICUIATE AND SULFUR DIOXIDE)^
PHOSPHATE ROCK
H2SO4
EXIT (GASEOUS FLUORIDEl
EXIT (AMMONIA, PARTICULATE)
EXIT (PARTICULATE)
EXIT (AMMONIA, PARTICULATE,
RUN Of PILE PRODUCT ,
BAGGING PRODUCT
GRANULATED.
PRODUCT
Figure 3.5.8 Normal superphosphate plant.
3-72
-------
Triple superphosphate, which is also referred to as
double or concentrated superphosphate, is produced through
the reaction of phosphate rock and phosphoric acid. Unlike
normal superphosphate, the production of triple superphosphate
is usually a continuous operation in large plants located
near phosphate rock deposits.
Two major processes are used in the production of triple
superphosphate. The first uses a mixing cone to achieve
initimate contact between the acid and rock. The resulting
mix falls on a conveyor belt which moves the material to the
curing building. After curing for 30 to 60 days, the product
is sold as run-of-pile or is granulated in separate equipment.
The second process produces granulated fertilizer
directly. Acid and phosphate rock are placed in mixing tanks,
fed through a plunger for intimate mixing and release of some
of the effluent gases, and then dried in a rotary dryer. The
product is a directly granulated material which is rather
hard and dense, and normally not amenable to ammoniating.
Figure 3.5.9 is a simplified flow diagram for a triple super-
phosphate plant.
3-73
-------
EXIT
(FLUORIDE)
i I
EXIT
(AMMONIA, FLUORIDE AND PARTICULATE)^
PHOSPHATE ROCK
PHOSPHORIC ACID
EXIT
(FLUOtlOE)
EXIT
(P ARTICULATE, FIUOHIOE AND SULFUR OXIDE)
EXIT (PARTICULATE).
PHOSPHATE ROCK
Figure 3.5.9 Triple superphosphate plant.
Diammonium phosphate is produced from phosphoric acid,
ammonia, and sulfuric acid. Ammonia and sulfuric and
phosphoric acids are mixed in a reactor and the product of
the reactor is pumped as a slurry to a rotary ammoniator.
Ammonia is sparged underneath the mixing bed in the ammoniator
to achieve the desired ammonia level. While the equipment
is rotating, agglomeration takes place and the ammoniation
is completed. The diammonium phosphate granules are dis-
charged into a rotary dryer, and then through a screening
station, a rotary cooler, and finally conveyed to storage.
A simplified flow diagram for a diammonium phosphate plant is
shown in Figure 3.5.10.
3-74
-------
EXIT
(FLUORIDES, AMMONIA, PARTICULATE)
EXIT
(FLUORIDES, AMMONIA. PARTICULATE)
EXIT
FLUORIDES, AMMONIA
AMMONIA AMMONIA
PHOSPHORIC ACIb
AMMONIA
V
V
FUEL DIAMMONIUM PHOSPHATE
GRANULES
Figure 3.5.10 Diammonium phosphate plant.
Atmospheric Emission - The gases released from the acidulation
of phosphate rock in normal superphosphate production contain
silicon tetrafluoride, carbon dioxide, steam and sulfur
dioxides. From 20 to 30 percent of the fluorine in the
phosphate rock is evolved during the acidulation and curing
operations. Vent gases from the granulator-ammoniator may
contain ammonia, silicon tetrafluoride, hydrofluoric acid,
ammonium chloride, and fertilizer dust. Emissions from the
final drying of granulated product include gaseous and
particulate fluorides, ammonia, and fertilizer dust.
3-75
-------
In triple superphosphate plants/ exit gases from plants
producing nongranular products will contain considerable
quantities of silicon tetrafluoride, some hydrogen fluoride/
and small amounts of particulates. Fluorides are also emitted
from the curing buildings. The emissions from run-of-pile
granulated superphosphate are mostly dust and fumes, especially
from the dryer and cooler.
The major pollutants from diammonium phosphate production
are fluorides, particulates, and ammonia. Vent gases from the
ammoniator tanks are the major source of ammonia emissions.
Control Systems - Spray towers, grid packed towers, and high
velocity jet scrubbers are used to control fluoride and
particulate emissions. Current practice is to send gases
with either copious quantities of water or with dilute
fluosilicic acid.
In triple superphosphate production, wet scrubbers are
the primary method for controlling emissions of gaseous
fluorides and particulate emissions. Packed towers, venturi
scrubbers, wet-pad and impingement scrubbers have been used.
Control of emissions from fertilizer granulation involves
collection of dry dust from rotary dryers, rotary coolers,
and gas and dust from liquid-solid reactor units. Various
3-76
-------
high efficiency cyclones have been used for removal of dust
in exit gases, followed by a wet scrubber to further reduce
the dust content and to remove the acid constituents.
Compliance Schedules - Figure 3.5.11 illustrates an expeditious
schedule for installation of a wet scrubber.
Sources of Additional Information
Type of
Source Information*
1. Handbook of Emissions and Control
Practices for Stationary Particulate
Pollution Sources P, E, C
NTIS No. 203-522
* P = Process description
E = Emission rates
C = Control devices
3-77
-------
Figure 3.5.11 Schedule for installation of a wet scrubber on phosphate
fertilizer operation for particulate and gaseous fluoride emissions control
u>
I
•j
00
Milestones
• - Activity and duration in weeks
MILESTONES_
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment Is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
1
2
3
4
5
ACTIVITIES
Designation
A-C Preliminary investigation
A-B Source tests
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare preliminary control plan and compliance
schedule for agency
F-G Agency review and approval
G-1 Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.6 Primary Metallurgical Processes
3.6.1 Metallurgical Coke
Process Description - Coke, an essential component in the
manufacture of iron and steel, is the residue from the
destructive distillation of coal. By-product coking, which
is by far the most common process in the U.S., is a batch
process involving batteries of 50 ovens or more. These slot
coke ovens, in which coal is heated in the absence of air,
are narrow refractory channels. Gas-fired flues between
adjoining ovens keep the ovens at coking temperature.
Initially coal is blended to give uniform coking character-
istics, then pulverized in hammermills and transferred to a
storage silo above the battery of ovens. A weighed portion of
coal is then discharged into a larry car, which is a wide-gauge
vehicle fitted with coal hoppers. The coal is transferred from
the hoppers into three to six opened coal-charging ports above
an empty oven. The oven-charging ports are then closed for the
duration of the 15 to 40 hour coking cycle.
As the charged coal is heated, the ovens emit a wide range
of organic compounds, which are collected in standpipes or
exhaust flues. These gases are sent to a by-product recovery
section for separation and recovery of such by-products as tar,
light aromatic compounds, ammonia liquor, and coke oven fuel
gas.
3-79
-------
Upon completion of the coking cycle, both end oven doors
are opened and the incandescent coke is forced into a hot-coke
car at one end of the oven by a large pusher ram at the opposite
end. The hot-coke car, or quenching car, moves the coke to a
quenching tower, a chimney-like structure in which the coke is
deluged with water. The damp, quenched coke is then deposited
in a sloping wharf, in which it drains and cools to a reasonably
uniform moisture content and temperature. Figure 3.6.1
illustrates the overall coking process.
Atmospheric Emissions - The primary pollutants from coke manu-
facture are coal and coke dust, sulfur oxides, light hydro-
carbons and aromatics, carbon monoxide, nitrogen oxides, and
reduced sulfur compounds. Emissions can occur during coal
handling, charging, pushing, and quenching. The emission sources
of primary concern are charging, pushing and quenching, and
combustion of the coke-oven gas.
Major emissions occur at the point of charging the coal
to the oven, since the rapid heating of the coal causes
volatilization of gases from the coal mass. These gases escape
to the atmosphere through the charging ports unless controlled.
Emissions also occur in the early stages of coking because of
leaks at the charging ports and around the sealed end doors.
3-80
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RAW COAL STORAGE
PULVERIZER
PREPARED COAL BINS
OIL
COAL BLENDING
AND MIXING
COAL BUNKEP
LARRY CAR
AIR
COKE OVEN
1
HOT -COKE
CAR
WATER,-
QUENCH
TOWER
COKE WHARF
COKE CRUSHER
BY-PRODUCTS
RECOVERY
SYSTEM
COKE OVEN
FUEL GAS
SCREENING
•TAR
•CHEMICALS
MISCELLANEOUS
" FU:L USAGES
MISCELLANEOUS
FUEL USAGES
• BLAST FURNACE
Figure 3.6.1 Metallurgical coke manufacturing
3-81
-------
Coke-oven gas recovered in the by-product recovery system
typically contains 3.5 to 4.5 grains per SCF of hydrogen
sulfide. The coke-oven gas used for fuel in heating or under-
firing the coke ovens and for other combustion operations results
in sulfur oxides emissions unless the hydrogen sulfide has
been removed.
Emissions resulting from discharge of the coke from the
ovens consist of smoke from any incompletely coked coal and
dust released as the coke is pushed into the hot-coke car.
Quenching of the hot coke results in a fine coke breeze
formed during the pushing of the hot-coke car and as water is
flash-evaporated within the coke itself. In addition, contam-
inated water, which is often used for quenching, can cause
emissions of ammonia and phenol vapors.
Control Systems - A procedure commonly used to reduce emissions
during coal charging is termed "charging on the main". A
steam ejector in the ascension pipe produces a draft in the oven
during the charging period which casues the gases to be pulled into
the gas collector main. Although it has undergone some
improvements, this technique is generally considered to be
ineffective. The two most feasible improvements are charging on
the main with closed coal ports and pipeline charging. Charging
3-82
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on the main with closed coal ports can be readily incorporated
into an existing plant. Features of this system include
sequencing of coal charging from the larry car with charging
port lids off only during charging, maintenance of a steady
negative pressure in the oven, and continual draw-off of evolved
gases. Pipeline charging involves preheating coal to drive off
moisture and transporting it by pipeline. Although a 40 to 50
percent increase in oven capacity can be realized with this
method, it is considerably more expensive, requiring far more
extensive equipment changes than charging on the main with
closed coal ports. Furthermore, the capacity of the by-product
recovery system must be increased to utilize the increase in
oven capacity.
Several systems have been considered for control of
emissions resulting from the discharge of newly produced coke.
One system recently put in operation consists of an enclosed
quench car which is attached to a second car that carries
the wet scrubber unit. During the pushing operation, emissions
are collected in the hood and withdrawn through the coupled
duct work between the cars to the wet scrubber unit.
3-83
-------
For removal of H2S from coke oven gas, the vacuum
carbonate process is the most widely accepted method applied
on a large scale at present. Hydrogen sulfide is absorbed
by a sodium carbonate stream and then released in a concen-
trated H2S stream by steam stripping. By this method the
H2S level in the gas stream can be reduced by about 93 per-
cent. A sulfur-recovery plant is normally used in conjunction
with the vacuum carbonate process to convert the recovered H,,S
into elemental sulfur. Certain newer processes, notably the
Stretford and Takehax processes, can remove 99% or more
H S but provisions must be made to handle the liquid effluent.
Compliance Schedules - Figures 3.6.2 and 3.6.3 illustrate
reasonable schedules for installation of charging on the main
with closed coal ports and pipeline charging systems for
existing coke oven batteries. Differences in existing equipment
may alter certain parts of the schedule.
Figure 3.6.4 represents an estimated schedule for
installation of a pushing hood system for emissions control
during discharging of newly produced coke from existing coke
oven batteries. Since only one pushing hood system is in
operation in the U.S., and the delay in obtaining railroad
cars required for this control system, this schedule must be
considered a rough approximation.
3-84
-------
Sources of Additional Information
Source Type of
Information*
(1) Evaluation of Process Alternatives
to Improve Control of Air
Pollution from Production of
Coke
NTIS: PB-189-266 P, E, C
(2) Kirk-Othmer. "Encyclopedia of
Chemical Technology." A. Staden
(ed.)f Interscience Publ., New
York, New York, 1969. Vol. 19,
p. 383 C
(3) Control Techniques for Sulfur
Oxide Air Pollutants, 2nd Edition
Environmental Protection Agency E, C
* P = Process description
E = Emission rates
C = Control devices
3-85
-------
Figure 3.6.2
Schedule for installation of coal
charging on the main with closed
coal ports for an existing battery.
.
J
4
u>
I
00
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-------
Figure 3.6.3 Schedule for installation of pipeline charging system
for an existing battery .
1
L
LL
4
3
\
co
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
Date of submirtal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed .
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process rie in.
Equipment start up and source testing.
ELAPSED TIME (WEEKS)
_£_
Jo-
-------
Figure 3.6.4 Schedule for installation of a hooded grind car
system for control of particulate emissions
during pushing and quenching operations.
.4.
1
*
J
4
5
U)
I
00
00
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3-4
4-5
ELAPSED TIME (WEEKS)
Date of submtttal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,.
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
70
-------
Figure 3.6.5 Schedule for installation of vacuum carbonate
scrubbing process .
13
J£
CO
I
CO
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3-4
4 -5
ELAPSED TIME (WEEKS)
Dote of submittol of finol control plon to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-------
Figure 3.6.6. Schedule for installation of a
sulfur-recovery unit (Glaus plant)
I_L
j
4I
1 ^
I
WD
O
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3 -4
4 -5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
ELAPSED TIME (WEEKS)
JJL.
-------
3.6.2 Iron and Steel
Process Description - Figure 3.6.7 illustrates the overall
process flow at an integrated iron and steel mill. Iron ore
in either pellet or sinter form is fed to the blast furnace,
along with limestone and coke, where it is reduced to form
pig iron. The pig iron is then refined to steel in open-
hearth, electric arc, or basic oxygen furnaces. The molten
steel from the furnaces is cooled and undergoes a variety of
shaping and forming operations to produce billets, slabs, or
rolls, which are then heat- and surface-treated.
Ancillary operations at an integrated steel mill include
coke manufacture and sintering. Coke manufacture, resultant
emissions, and control methods are described in Section
3.6.1. In the sintering operation, iron ore fines and
recovered dust from various emission sources are mixed with
coke fines and limestone, and fed to the sintering machine
to form a fused mass suitable for use as feed to the blast
furnace.
Atmospheric Emissions - Emissions from the blast furnace
consist primarily of particulates and carbon monoxide; sulfur
in the coke and ore is trapped in the slag and hence is not
emitted. High-efficiency particulate collection devices are
3-91
-------
I
i*Q
ro
TO SINTEI flANT
QUENCHING
TOWEH
COKING
Figure 3.6.7 Integrated iron and steel facility.
-------
not required as part of the process to prevent fouling of the
checkerwork used for heat recovery. Between 2000 and 3000
pounds of CO per ton of pig iron are produced. Approximately
25 percent of this is sent to the blast furnace stoves to
heat the incoming air. The remainder is used to fire boilers,
coke ovens, and soaking pits.
Emissions from the steel making furnaces consist pri-
marily of particulates and CO; to a limited extent, SO« may
also be emitted from open-hearth furnaces due to the sulfur
content of the fuel. Particulate emissions range from
approximately 5 pounds per ton of steel produced for electric-
arc furnaces without oxygen lancing to 60 pounds per ton for
basic oxygen furnaces. Carbon monoxide emissions range from
essentially nil for open-hearth furnaces to 150 pounds per
ton for basic oxygen furnaces.
Sinter machines emit particulates and sulfur oxides;
fluorides and other potentially hazardous materials may also
be emitted depending upon the composition of the ore. The
major sources of particulate emission are the windbox
discharge gases and the discharge end of the sinter machine.
Particulate emissions from each source are approximately 20
pounds per ton of sinter produced. Sulfur dioxide is emitted
3-93
-------
in the windbox discharge gases. Approximately 70 percent of
the sulfur content of the feed mixture can be emitted as
sulfur oxides.
Control Systems - Particulate emissions from steel furnaces
can be controlled by electrostatic precipitators, fabric
filters, and wet scrubbers. The trend has been toward high-
energy venturi scrubbers because of the relative insensitivity
of scrubber collection efficiency to variations in effluent
stream conditions. Pressure drops of 60 to 100 inches water
gauge are usually required, depending upon emission charac-
teristics. Problems associated with application of electro-
static precipitators result from variations of effluent stream
volume, moisture content, and temperature. The use of fabric
filters has been essentially limited to electric-arc furnace
installations.
Carbon monoxide in the effluent is usually burned in the
hood system, except in a few basic oxygen furnace configura-
tions, where it is recovered for use as a fuel. The gases
are then cooled, usually by water sprays prior to the
particulate control device.
Fabric filters, electrostatic precipitators, and wet
scrubbers can be used to control sinter plant emissions.
Special materials of construction are required for wet
3-94
-------
scrubber installations because of the sulfur content of the
gas stream. In design of electrostatic precipitator instal-
lations, particular attention must be paid to the composition
of the sinter; use of self-fluxing sinter impairs precipitator
collection efficiency because of its higher resistivity.
Fabric filter installations are designed with air to cloth
2
ratios of approximately 2 to 3 cfm/ft and predominantly use
fiberglass bags.
Compliance Schedules - Expeditious schedules for installation
of a high-energy wet scrubber, an electrostatic precipitator,
and a fabric filter on steel making furnaces or sinter plants
are shown in Figures 3.6.8, 3.6.9, and 3.6.10, respectively.
Sources of Additional Information
Type of
Source Information*
1. The Making, Shaping and Treating of
Steel, Ninth Edition P
U.S. Steel Corporation,
Pittsburg, Pennsylvania
2. A Systems Analysis Study of the
Integrated Iron and Steel Industry P, E, C
NTIS Publication No. PE 184-577
3. A Manual of Electrostatic
Precipitator Technology C
NTIS Publication No. PB 196-381
* P = Process description
E = Emission rates
C = Control devices
3-95
-------
Figure 3.6.8 Compliance schedule for installation
of a high energy wet scrubber
for particulate pollutant control.
OJ
i
U3
CT\
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submitfal of final control plan to appropriate agency 0
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed^
Date by which final compliance is achieved a
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.6.9 Compliance schedule for installation
of electrostatic precipitator
for particulate pollutant control.
U)
i
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-6
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-*ite construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.6.10 Compliance schedule for installation
of a baghouse for particulate pollutant control.
CO
I
VD
OO
= Milestones
*• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
? Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
- 14
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.6.3 Primary Aluminum
Process Description - Bauxite is the principal ore of aluminium.
It consists of aluminium oxide and various impurities, such as
iron oxide, aluminium silicate, and titanium dioxide. The
production of alumina, which consists of separating it from the
impurities in the bauxite ore, is accomplished entirely by
chemical means. In the Sainto-Claire Deville process, the sodium
aluminate is prepared by calcining the bauxite with sodium
carbonate at 1100°C; the calcined material is then washed with
alkali, yielding a sodium aluminate solution from which the alumina
is precipitated by carbon dioxide. In the Bayer process, a more
recent development, the separation is carried out entirely in the
aqueous phase, taking advantage of the solubility equilibria of
the alumina hydrates in a caustic soda solution.
Aluminium is produced electrolytically from alumina. The
alumina is decomposed by a continuous current that flows through
the electrolytic cell containing alumina dissolved in molten
cryolite.
The electrolyte cell consists of a carbon-lined box containing
a pad of molten aluminium that serves as a cathode, a carbon anode,
and the alumina-cryolite bath. Usually 100 cells, commonly called
pots, are connected in series to form a potline, each plant oper-
ating three to ten potlines.
3-99
-------
In addition to fluorine, exhausts from the cells contain
sulfur dioxide from the sulfur impurities in the anodes,
tarry hydrocarbons, alumina and carbon particles, and oxides of
carbon.
Other atmospheric emissions in aluminum reduction plants are
caused by certain peripheral operations. Among these are the
anode and paste manufacturing, which emit high-molecular-weight
hydrocarbons and small carbon particles. The molten metal purifi-
cation, alloying, and casting operations cause further emissions,
mainly chlorides of aluminum and small amounts of hydrogen chloride
and chlorine. A third peripheral operation related to the manu-
facture of anode and paste is the production of calcined petrol-
eum coke. This operation involves heating the material to drive
off moisture and volatiles, and transforming the carbon from an
insulating to a conducting carbon.
Control Systems - As noted above, the principal potential pollu-
tants in the electrolytic cell effluent are (1) particulate solids,
including solid fluorides and alumina, (2) gaseous hydrogen fluor-
ide, and (3) condensed hydrocarbon C (from Soderberg cells).
Because of specific problems encountered in use of each type
of electrolytic cells, the control systems for each are discussed
separately.
3-100
-------
1) Vertical Spike Soderberg Cell - Gases and dusts from the
bath can be collected by a hood around the bottom of the anode.
The dust content of the raw gas is reduced in the collection
system by burning the tar components in combination with the
carbon monoxide with a burner located in the collection channel.
The final treatment of the gas consists of passage through a dry
cyclone to collect the coarse particles (in some installations
followed by a filter) followed by two to three stages of wet
scrubbers that use water to recover the hydrogen fluoride. A
final stage of alkaline scrubbing may be required to remove
sulfur dioxide and the remaining fluoride.
2) Horizontal Spike Soderberg Cells - The arrangement of the
spikes in horizontal spike soderberg cells makes it difficult to
effect a good seal around the anode, and therefore large quantities
of diluting air enter the gas cleaning system. The dilution is so
great that combustion to destroy the tars in neither economical
nor feasible.
One installation in Canada reportedly has overcome the
problem of tar interference in the wet scrubber operation by using
a turbulent bed scrubber. The combined action of an upward flow
of gas and the downward flow of the scrubbing liquid maintains the
spheres in a loose assembly and promotes intimate mixing. Turbu-
lence around the loose spheres keeps them free of tars and dirt.
3-101
-------
Field tests have shown that this type of scrubber can remove 90
percent or more of hydrogen fluoride.
(3) Prebaked Cells - When cells with prebaked anodes are
used, it is difficult to draw off furnace gases in concentrated
form directly from the cells because of the large number of
anodes. On these pots, an exhaust hood usually encloses the
active area and maintains it at a slightly negative pressure.
Pollution control equipment used with the prebaked cell
consists of a dry cyclone or electrostatic precipitator for
removal of particulates, followed by a wet scrubber to absorb the
highly soluble hydrogen fluoride, and the remaining traces of
fluoride particulates.
A more recent method for recovering gaseous fluorides from
prebaked potlines, entails the use of a heavy bed of alumina,
which is continually added on the upper crust of the cell.
Contaminants are removed by filtering the gases through the bed
of alumina; stray particulates are captured by a baghouse further
down stream.
Compliance Schedules - Figures 3.6.11 , 3.6.12 , and 3.6.13 , respec-
tively, illustrate expeditious schedules for installation of a
wet scrubber system, a fabric filter, and an electrostatic
precipitator. The complexity of the ductwork and hooding systems
required for effective control were considered in developing the
3-102
-------
schedules. Additional time was included to reflect the extra
work required for their design, fabrication, and installation.
No compliance schedule is shown for installation of dry cyclones
or afterburners since they can be installed relatively quickly
and construction can be accomplished within the elapsed time
shown for any of the other control devices mentioned.
Sources of Additional Information
Source Type of Information
1) Kirk Othmer's Encyclopedia of P
Chemical Technology.
Vol. 1, 2nd Edition
Interscience Publishers
2) Air Pollution Control Field P
Operations Manual.
Vol. Ill, Revised Edition
System Development Corp.
Contract No. CPA 70-122
3) Air Pollution Abatement on Primary P/C,E
Aluminum Potlines.
Rush, D. et al.
Journal of the Air Pollution Control
Association,
Vol. 23, No. 2, Feb. 1973
3-103
-------
Figure 3.6.11 Schedule for installation of a wet scrubber
on a primary aluminum reduction operation for
particulate pollutant and fluoride emissions control.
u>
I
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-sife construction or installation of emission control equipments
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-£ Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.6.12 Schedule for installation of a fabric filter
on a primary aluminum reduction operation
for particulate pollutant control.
= Milestones
~~ * = Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source rests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.6.13 Schedule for installation of an electrostatic
precipitator on a primary aluminum operation
for particulate pollutant control.
U)
i
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.6.4 Ferroalloys
Process Description - Ferroalloys, the generic term for alloys
consisting of iron and one or more other metals, are used for
deoxidation, alloying, and graphitization of steel. They can be
classified into three basic types according to the major non-
ferrous constituent: (1) silicon-based alloys, such as ferro-
silicon; (2) manganese-based alloys, such as ferromanganese;
and (3) chromium-based alloys, such as ferrochromium.
Blast furnaces and electric arc furnaces are both used to
produce ferroalloys. Ferromanganese is produced in blast
furnaces by the reduction of iron ore and manganese ore with coke
in the presence of limestone. Approximately 75 percent of ferro-
alloys, however, are produced in electric arc furnaces.
Other ferroalloy manufacturing processes, used to a much
lesser extent, are the alumino silico-thermic process and the
electrolytic deposition process.
Atmospheric Emissions - Particulates emitted from the furnace are
the primary emission problem. The chemical and physical proper-
ties of the particulates depend upon the alloy being produced
and the type of furnace. Particle sizes generally range from
0.1 to 1.0 micron, with a geometric mean of approximately 0.3
micron.
3-107
-------
Particulate emission from silicon alloy manufacture
contains a high percentage of Si02. Some tars and carbon
are also present due to the coal, coke or wood chips used in the
charge. Chromium furnaces produce Si02 fume similar to a ferro-
silicon operation with some additional chromium oxides. Manga-
nese operations produce a brown fume, largely a mixture of SiO»
and manganese oxides.
Control Systems - Blast furnace emissions are most commonly
controlled by a high-energy wet scrubber. Electric furnaces can
use either the open or closed furnace hooding design. In open
furnaces all the CO produced burns with induced air at the top
of the charge, resulting in a large volume of high-temperature
gas. In closed furnaces most or all of the CO is withdrawn from
the furnace without combustion with air.
High-energy venturi scrubbers are the most commonly used
control device for both open and closed furnaces. The pressure
drop required for high-efficiency particulate collection is
about 60 inches water gauge for a ferrosilicon or ferrochrome-
silicon operation. Substantially all of the sulfur in the
reducing agent appears in the gas phase, creating a potential
corrosion problem for liquid recycle systems unless neutralizing
agents or special materials of construction are used.
3-108
-------
Fabric filters can also operate effectively provided the
gas temperature is reduced to below 500°F. However, in silica
fume collection, a buildup of electrostatic charge occurs,
leading to a high residual pressure drop across the bags.
Electrostatic precipitators have been used only to a limited
extent.
Compliance Schedules - Figures 3.6.14, 3.6.15, and 3.6.16, respec-
tively, illustrate expeditious schedules for installing a high-
energy wet scrubber system, a fabric filter, and an electrostatic
precipitator on ferroalloy furnaces.
Sources of Additional Information
Type of
Source Information*
1) Handbook of Emissions, Effluents P/E,C
and Control Practices for
Stationary Particulate Pollution
Sources.
NTIS Publication No. PB-203-128
* P = Process description
E = Emission rates
C = Control devices
3-109
-------
Figure 3.6.14 Schedule for installation of a wet scrubber
on a ferroalloy furnace for particulate pollutant control.
LO
I
= Milestones
•• = Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Dote of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.6.15 Schedule for installation of a fabric filter
with pre-cooler on a ferroalloy furnace
for particulate pollutant control.
= Milestones
——*• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.6.16 Schedule for installation of an electrostatic
precipitator on a ferroalloy furnace.
MILESTONES
1
2
3
4
5
ACTIVITIES
Designotion
A-C
A-B
C-D
D-E
E-F
F-G
G-!
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency*
[Date of award of control device contract.
Date of initiation of on-«ite construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed B
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
I 01
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.7 Secondary Metallurgical Processes
3.7.1 Aluminum
Process Description - Secondary aluminum operations involve
remelting of metal alloys to make castings and ingots. Depending
on the source of the aluminum, the process may also include
removal of impurities in the melt and introduction of alloying
metals to obtain desired properties in the casting. Figure 3.7.1
illustrates the secondary aluminum process.
Impurities are usually removed by fluxing, a term applied
to any process in which materials are added to the melt to aid
in the removal of gases, oxides, or other impurities but do not
remain in the final product. Alloying is accomplished by adding
a compound containing the desired alloying metal. For example,
zinc chloride and zinc fluoride can be used to increase the zinc
content of aluminum alloys.
Demagging, which reduces the magnesium content of the melt,
is accomplished by injecting chlorine gas into the molten bath.
The chlorine reacts to form primarily magnesium chloride and
some aluminum chlorides, which further react with magnesium to
form additional magnesium chloride and aluminum.
The metal is melted in crucible or reverberatory furnaces.
Crucible furnaces are indirectly heated and are used for melting
small quantities, usually less than 1000 pounds. Reverberatory
3-113
-------
Scrap Aluminum
Containing other Metals
co
I
Scrap Aluminum Parts
Emissions
Flux
Emissions
Aluminum
Borings & Turnings
(Dirty Scrap)
Fuel-
Al laying
Compounds
Emissions
Scrap
Cleaning
Furnace
Reverberatory
Furnace
Molds
Metal
Figure 3.7.1 Secondary aluminum process.
-------
furnaces are directly fired and are used for medium and large
batches of 2,000 to 20,000 pounds.
Sweat furnaces are commonly used in secondary aluminum opera-
tions to separate the aluminum from iron and other metals.
Facilities that process borings or turnings from fabricating
operations often use gas- or oil-fired furnaces to burn off the
cutting oils and grease before the metal is charged into the
melting furnace.
The core making and sand handling systems are integral parts
of the foundry. These processes, their emissions, and control
methods, with expeditious schedules for installing the control
devices, are described in Section 3.7.8.
Atmospheric Emissions - The melting of clean aluminum pigs and
foundry returns without the use of fluxes does not create signifi-
cant atmospheric emissions. The melting of aluminum scrap,
however, requires air pollution control equipment to prevent the
discharge of excessive emissions, consisting primarily of magnes-
ium and aluminum chloride fumes, which react with moisture in the
air to form magnesium and aluminum oxides and hydrogen chloride.
Particulate emissions from the sweating furnaces amount to
approximately 15 pounds per ton of metal processed. Reverberatory
furnaces emit from 2 to 4 pounds per ton; the chlorination station
3-115
-------
emits about 1000 pounds of particulates per ton of chlorine
consumed.
Control Systems - Fabric filters and wet scrubbers are used to
control emissions from reverberatory and crucible furnaces, with
fabric filters predominating. An afterburner is also required
on sweating furnaces because the effluent is oily and combusti-
ble. In operation of a fabric filter/afterburner combination the
exhause gases of the afterburner must be cooled by either evapo-
rative or radiant cooling to protect the fabric. Air-to-cloth
ratios of approximately 2:1 are used for the fabric filter.
Dacron is the most commonly used fabric. High-energy venturi
scrubbers require as much as 40 to 50 inches water gauge pressure
drop to provide the required collection efficiencies.
For the chlorination station, a wet scrubbing system consist-
ing of a high-energy venturi contactor followed by a gas absorp-
tion tower, is required for effective control of both the sub-
micron particulates and the HC1 and C12 emissions. Pressure drops
of 50 to 60 inches water gauge may be required to control particu-
late emissions effectively.
Compliance Schedules - Figure 3.7.2 illustrates an expeditious
schedule for installing either a fabric filter or fabric filter/
afterburner control system. Figure 3.7.3 illustrates an expedi-
tious schedule for installing either a wet scrubber or wet
3-116
-------
scrubber/afterburner control system. Figure 3.7.4 illustrates
an expeditious schedule for installation of an afterburner on a
scrap cleaning furnace.
Figure 3.7.5 illustrates an expeditious schedule for
installing a custom designed baghouse or baghouse/afterburner
system where it is required due to such factors as space
limitations and unique process configurations. This schedule
is sufficient to accommodate simultaneous modification to a
furnace if required.
Sources of Additional Information
Type of
Source Information*
1) Air Pollution Engineering Manual P,C
Public Health Service Publication
No. 999-AP-40
2) Exhaust Gases from Combustion and P,C
Industrial Processes
NTIS PB 204-861
3) Study of Technical and Cost Information P,E,C
for Gas Cleaning Equipment in the
Lime and Secondary Non-Ferrous
Metallurgical Industries
NTIS PB 198-137
* P = Process description
E = Emission rates
C = Control devices
3-117
-------
Figure 3.7.2 Schedule for installation of a fabric filter or
fabric filter/afterburner control system
for particulate pollutant control.
co
I
CO
Milestones
•" = Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency0
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.7.3 Schedule for installation of a wet scrubber or
wet scrubber/afterburner control system
for particulate pollutant control.
U)
i
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q -3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.7.4 Schedule for installation of an afterburner for control
of hydrocarbon and combustible particulate emissions.
u>
i
= Milestones
• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.7.5 Schedule for installation of
custom-designed fabric filter
for particulate pollutant control.
10
-H3
/e
(0
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3-4
4 -5
ELAPSED TIME (WEEKS)
Date of submiftal of final control plan to appropriate agency.
Date of award of control device contract..
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site .
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
60
-------
3.7.2 Brass and Bronze
Process Description - Brass and bronze production involves a wide
variety of melting, refining, and casting operations to produce
the copper or copper-based alloys. Raw materials in the form of
ingots and/or scrap are melted in a furnace and various fluxes
are added to refine the metal. The molten metal is then poured
into smaller pots and transferred to the casting area, where it
is poured into molds. After the metal cools, the sand mold
material is separated from the metal in the shake-out area. The
casting is then cleaned and processed, and the sand mold material
is recycled.
A number of melting furnaces are used in this industry,
including gas- and oil-fired reverberatory and rotary furnaces,
and electric induction units.
The core making and sand handling systems are integral parts
of a brass and bronze foundry. These processes, emissions, and
control methods plus expeditious schedules for installing the
control devices, are described in Section 3.7.8.
Atmospheric Emissions - The melting operation represents the
primary source of particulate emissions. Particulate composition
depends on the metals being melted and the flux material used.
The quantity of particulate emitted depends primarily on the type
3-122
-------
of melting furnace used. Alloys containing zinc, tin, and
magnesium tend to produce higher emission levels because of their
higher volatility. Direct-fired furnaces, such as the reverbera-
tory furnace, produce higher emission levels than indirect-fired
units.
Careful temperature control, proper flux cover, and addition
of alloying metals before the melt is started all tend to reduce
emissions.
Other sources of particulate emissions include the mold and
casting handling and preparation areas. These sources are
relatively minor as compared with the furnace emissions.
Control Methods - Both process changes and control systems can
be used to reduce emissions. The use of crucible or pot furnaces,
fired externally with gas or light oil, or the use of electric
induction furnaces, can greatly reduce the amount of fume genera-
ted in the melting processes.
Particulate control can also be achieved by the installation
of fabric filter systems. The small particle sizes and the
potential presence of hazardous metal compounds require a highly
efficient control system. Air-to-cloth ratios on the order of
3:1 are commonly used.
3-123
-------
Compliance Schedules - An expeditious schedule for installation
of a fabric filter to control emissions from a brass and bronze
foundry is shown in Figure 3.7.6.
Sources of Additional Information
Type of
Source Information*
1) Air Pollution Aspects of Brass E,C
and Bronze Smelting and Refining
Industry
National Air Pollution Control
Administration AP-58
2) Air Pollution Engineering Manual P,C
Public Health Service Publication
999-AP-40
* P = Process description
E = Emission rates
C = Control devices
3-124
-------
Figure 3.7.6 Schedule for installation of a fabric filter on a
brass and bronze foundry for particulate pollutant control.
U)
i
M
NJ
= Milestones
*" - Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-sire construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.7.3 Steel
Process Description - Steel foundries differ from the basic iron
and steel plants since their primary raw material is scrap steel.
They produce cast steel, usually for heavy industrial uses, such
as bulldozer frames and locomotive wheels.
Three types of furnaces are in common use: direct electric-
arc, electric induction, and open hearth. Scrap, pig iron,
ferroalloys, and limestone are charged to the furnace. Refined
steel is produced in the melt by oxidizing the impurities,
reducing the iron oxide, and adding the desired alloying constit-
uents.
Atmospheric Emissions - Particulate emissions from steel foundry
operations include iron oxide fumes, sand fines, graphite, and
metal dust. Hydrocarbons can also be emitted if dirty scrap is
charged. Primary factors influencing the quantity of pollutants
emitted are the quality and cleanliness of the scrap and the
amount of oxygen lancing used.
Particulate emissions from the electric arc furnace range
between 4 and 40 pounds per ton, averaging about 13 pounds per
ton of metal processed. Emissions from open-hearth furnaces
average about 11 pounds of particulate per ton; electric induction
furnaces emit about 0.1 pound per ton of metal processed.
3-126
-------
Control Systems - Fabric filters and, to a lesser extent, wet
scrubbers are the most commonly used control devices. Air-to-
cloth ratios for the fabric filter should not exceed 2.5 to 1.
Dacron and glass fiber are the most commonly used fabrics.
Compliance Schedules - Figures 3.7.7 and 3.7.8, respectively,
illustrate expeditious schedules for installation of a fabric
filter and a wet scrubber.
Figure 3.7.9 illustrates an expeditious schedule for
installing a custom-designed fabric filter where it is required
by such factors as space limitations and unique process configu-
rations. This schedule can accommodate simultaneous modification
of the furnace if required.
Sources of Additional Information
Type of
Source Information*
1) Air Pollution Engineering Manual P,C
Public Health Service Publication
No. 999-AP-40
2) Exhaust Gases from Combustion and P,C
Industrial Processes
NTIS Publication No. PB 204-861
* P = Process description
E = Emission rates
C = Control devices
3-127
-------
Figure 3.7.7 Schedule for installation of a fabric filter
on a steel foundry furnace for particulate pollutant control.
MILESTONES
U)
1
NJ
oo
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submirtal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.7.8 Schedule for installation of a wet scrubber
on a steel foundry furnace for particulate pollutant control.
U)
i
M
ro
= Milestones
• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract,
3 Date of initiation of on-site construction or installation of emission control equipment *
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.7.9 Schedule for installation of a
custom designed fabric filter
for particulate pollutant control.
2.8
iO
-Hi}
IB
u>
I
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
\ -2
2 -3
3 -4
4 -5
Date of submittal of final control plan to appropriate agency.
Dare of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
ELAPSED TIME (WEEKS)
£8
38
-------
3.7.4 Gray Iron
Process Description - Gray iron foundries produce a heavy,
brittle metal commonly called cast iron, but named for its
characteristic gray-white color. Three types of furnaces
are in common use: cupolas, reverberatory furnaces, and
electric induction furnaces. Cupolas, which are used to
melt over 90 percent of the metal poured for gray iron
castings, range in capacity from 1 to 50 tons of metal per
hour. Electric furnaces are gaining in popularity, partially
because of their low emission rates. Reverberatory furnaces
are used in about 2 percent of the foundries.
Atmospheric Emissions - Emissions from cupolas consist pri-
marily of metallic oxides plus products of incomplete com-
bustion from the oils and grease adhering to the scrap.
Carbon monoxide is also emitted in significant amounts
because the cupola's atmosphere is oxygen deficient. Un-
controlled emission rates are approximately 15 and 150
pounds of particulates and carbon monoxide, respectively,
per ton of metal charged.
Control Systems - Afterburner/fabric filter systems are most
commonly used to control emissions. Afterburner/high-energy
wet scrubber systems are also used, but to a more limited
extent. Gas burners or torches are frequently installed
directly above the charging door to control carbon monoxide
3-131
-------
and, to some extent, odor emissions. The afterburner section
should be designed to allow a residence time of approximately
0.5 second and a minimum temperature of 1200°F. The gases
from the afterburner must be cooled by air dilution, radiant
cooling, or quenching with water to protect the fabric
filter. Air dilution and radiant cooling are usually preferred
since they minimize the chances of fabric blinding. Air-to-
cloth ratios for the fabric filter are typically 2 to 1.
Compliance Schedules - Installation of a fabric filter/
afterburner system usually requires furnace modification to
reduce the volume of exhaust air that must be treated.
Figure 3.7.10 illustrates an expeditious schedule for
installing a fabric filter/afterburner system with simul-
taneous modifications of the furnace, if required. Figure
3.7.11 illustrates an expeditious schedule for installation
of a high-energy wet scrubber.
Sources o;f Add-i-tional Information
Type of
Source Information*
1. Air Pollution Engineering Manual P, E, C
Public Health Service Publication
No. 999-AP-40
2. Systems Analysis of Emissions P, E, C
and Control in the Iron Foundry
Industry
NTIS No. PB 198-348
* P = Process description
E = Emission rates
C = Control devices
3-132
-------
Figure 3.7.10 Schedule for installation of a fabric filter/afterburner
control system for particulate pollutant control.
IO
IS
GJ
I
OJ
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3 -4
4 -5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of ort-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in,
Equipment start up and source testing.
ELAPSED TIME (WEEKS)
O
-------
Figure 3.7.11 . Schedule for installation of a high energy
wet scrubber system for particulate pollutant control.
u>
i
H
U)
= Milestones
*• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency»
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-f
f-G
G-l
1-H
H-J
J-2
- 2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approve! of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.7.5 Lead Smelting
Process Description - Three types of furnaces are used to
produce the common grade of lead: the pot furnace, the
reverberatory furnace, and the blast furnace or cupola.
Pot furnaces, which are indirectly fired, are used pri-
marily for alloying and refining. Reverberatory furnaces are
used in the processing of lead scrap metal in several ways,
including burnout, sweating, melting, and purification. The
burnout operation involves incineration of materials present
in the scrap, such as plastics, rubber insulation, wood, paper
and other combustible materials. In lead sweating operations,
lead is separated from a mixture of materials, many of which
have higher melting points than lead. The primary use of
reverberatory furnaces is for lead melting and purifying the
lead by removal of extraneous ingredients. Figure 3.7.12
illustrates a lead reverberatory furnace controlled by a fabric
filter.
The lead cupola is similar to the iron cupolas used in
ferrous smelting operations. Unlike the reverberatory furnace,
the cupola serve a very specific function: to reduce the
oxidized metal. The material charged consists of lead-contain-
ing alloys, slag, coke, and limestone, with some scrap cast
iron. Additional charges are added at intervals as the material
melts down.
3-135
-------
REVERBERATORY
FURNACE
SETTLER-
COOLERS
FABRIC
COLLECTOR
STACK
DISCHARGE
FAN A
GAS OR
OIL
COMBUSTION
AIR
I
LEAD
SCRAP
CHARGE
FUCL
{•>,:. (':'." '.'•:" ' '<•'• '•' '• ' "••' '•:•!
^"%Hfi|r-
B
1 1 :.t :^V^.!-TT1
AIR
LANCE
(
LE
— =4*
»•:•.:•:•.-.•. f.
L.
X
^
ft t iy
^ rlUA
»
s
^
— 1
s
»
^
. 1
.
1
\s
Y
T
FINES
1
,
\ /
Y
T
TO
•e*
_.
^ tf BLAST
DROSS | |
AD
PRODUCT
FURNACE
LEAD OXIDE TO
BLAST FURNACE
Figure 3.7.12 Lead reverberatory furnace.
The core making and sand handling systems are integral
parts of the foundry. These processes, their emissions, and
control methods, with expeditious schedules for installing the
control devices, are described in Section 3.7.8.
Atmospheric Emissions - Particulate emissions from the crucible
furnace are usually less than one pound per ton of material
charge. Because this material is extremely hazardous, however,
the process requires a high degree of control. Particulates
emitted from reverberatory and blast furnaces amount to approxi-
mately 130 and 190 pounds per ton of metal processed, respectively,
3-136
-------
Although particulates are usually the emission'of primary
concern, sulfur oxides, carbon monoxide, hydrocarbons, and
hydrogen chloride (from decomposition of chlorine-containing
materials) can also be emitted by oxidation of the sulfur content
of the materials charged to the furnace (e.g. lead batteries).
Control Systems - Particulate emissions are usually controlled
by fabric filters operating with air-to-cloth ratios of about
2:1. Orion fabric is frequently used. An afterburner system
may be required to complete combustion on reverberatory furnaces
burning significant amounts of scrap, followed by a fabric
filter or high-energy wet scrubber for particulate removal; the
scrubber is capable of removing soluble gases.
Compliance Schedules - Figures 3.7.13 and 3.7.14 illustrate
expeditious schedules for installation of a wet scrubber and a
fabric filter system, respectively. The schedule for the wet
scrubber system includes the time required to install the
associated waste water treatment equipment.
Sources of Additional Information
Type of
Source Information*
1. Air Pollution Engineering Manual P, C
Public Health Service Publication
No. 999-AP-40
3-137
-------
Study of Technical and Cost Information
for Gas Cleaning Equipment in the Lime
and Secondary Non-Ferrous Metallurgical
Industries. P, C, E
PB 198 137
* P = Process description
E = Emission rates
C = Control systems
3-138
-------
Figure 3.7.13 Schedule for installation of a wet scrubber system
on lead smelting furnaces for particulate pollutant
and gaseous emissions control.
u>
i
M
U)
VD
= Milestones
•• = Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
1
2
3
4
5
ACTIVITIES
Designation
A-C Preliminary investigation
A-B Source tests
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare preliminary control plan and compliance
schedule for agency
F-G Agency review and approval
G-l Finalize plans and specifications
1 -H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.7.14 Schedule for installation of an afterburner/baghouse
system on lead smelting furnace for particulate pollutant control.
4 x-N^/^Zf
CO
i
M
*>
O
= Milestones
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.7.6 Zinc Smelting
Process Description - Secondary zinc is melted in a variety
of furnaces for use in alloying, casting, and galvanizing.
These furnaces include crucible (pot), kettle, reverberatory,
and electric induction furnaces. Sources of the raw material
are ingots, rejected castings, and scrap.
The melting operation is essentially the same in all these
units. The zinc is melted and heated to its pouring temperature,
between 800 and 1100°F. Before the zinc is poured, fluxing
material may be added to separate the dross that accumulated
during the melting operation. Dross is formed by the impurities
charged with the metal and by oxidation during the melting and
heating cycles. The dross is skimmed from the surface of the
metal and the metal is poured into molds.
The core making and sand handling systems are integral
parts of a zinc foundry. These processes, their emissions, and
control methods, with expeditious schedules for installing the
control devices, are described in Section 3.7.8.
Atmospheric Emissions - Particulates emitted from zinc smelting
operations consist primarily of zinc oxide fumes. The emission
rate depends on the cleanliness and quality of the scrap and the
type of furnace used. Melting clean zinc scrap produces
3-141
-------
relatively low emissions, whereas with dirty scrap, the
particulate emission is approximately 25 pounds per ton of
metal produced.
The type of flux used can also affect the emission rate.
Although many fluxes now in use do not fume, a specific fuming
flux may be required for certain batches. For example, ammonium
chloride is sometimes used; when heated to the temperature of
the molten zinc, this compound decomposes into ammonia and
hydrogen chloride. The ammonia and hydrogen chloride subsequently
recombine to form a sub-micron fume of ammonium chloride.
Control Systems - Both process changes and control devices can
be used to reduce emissions. Use of electric induction furnaces,
clean scrap, and non-fuming fluxes can substantially reduce
emissions.
Fabric filters made of Dacron fabric are the most commonly
used control devices. The gases from the furnace must be cooled
to about 250°F through either quenching or radiant cooling.
Air-to-cloth ratios are typically between 2 to 1 and 3 to 1.
Compliance Schedules - Figure 3.7.15 illustrates an expeditious
schedule for installation of a fabric filter on a secondary
zinc furnace.
3-142
-------
Sources of Additional Information
Type of
Source Information*
1. Secondary Zinc Industry Emission
Control Problem Definition Study P, C
NTIS PB 201-739
2. Exhaust Gases from Combustion and
Industrial Processes P
NTIS PB 204-861
3. Air Pollution Engineering Manual P, E, C
PHS Publication No. 999-AP-40
* P = Process description
E = Emission rate
C = Control method
3-143
-------
Figure 3.7.15 Schedule for installation of a fabric filter
on a zinc smelting furnace for particulate pollutant control,
00
I
- Milestones
• - Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Dare by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
ELAPSED TIME (WEEKS)
J4
43
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q -3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.7.7 Magnesium Smelting
Process Description - Magnesium is smelted in steel pot furnaces
with capacities ranging between 500 and 5000 pounds per batch.
The raw material usually consists of scrap metal, magnesium
shavings and turnings, and similar materials. The heat source
is either natural gas, oil, or electric induction. A flux
covers the surface of the molten metal since magnesium will
burn in air at the pouring temperatures. The molten magnesium
is usually cast by pouring it into molds and the molds are
then annealed in ovens in an inert atmosphere.
Atmospheric Emissions - Particulates are the emissions of primary
concern. During the first few seconds following the charging of
the furnace, particulate may be emitted as a result of incomplete
combustion of oils and other organic materials adhering to the
scrap. Sub-micron metal oxides and chlorides can be emitted
during the entire melting and refining stages.
Particulate emissions from pot furnaces are estimated to be
approximately 4 pounds per ton.
Control Systems - Two types of control devices are in use,
baghouses and high-energy wet scrubbers.
3-145
-------
Compliance Schedules - Figures 3.7.16 and 3.7.17 illustrate
expeditious schedules for installation of a fabric filter and
a high-energy wet scrubber, respectively.
Sources of Additional Information
Type of
Source Information*
1) Exhaust Gases from Combustion and
Industrial Processes P, C
NTIS Publication PB 204-861
* p = Process description
E = Emission rates
C = Control devices
3-146
-------
Figure 3.7.16 Schedule for installation of a fabric filter
on a magnesium smelting furnace for
particulate pollutant control.
U)
i
H
= Milestones
*" - Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency°
2 Date of award of control device contract.
3 Date of initiation of on-site construction or inslaliation of emission control equipment =
4 Date by which on-site construction or installation of emission control equipment is completed.,
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
(_-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
figure 3.7.17 Schedule for installation of a wet scrubber system
on a magnesium smelting furnace for
particulate pollutant control.
u>
i
00
~ Milestones
•• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment 0
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
F-G
G-l
1-H
ri-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule For agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.7.8 Core Making and Sand Handling
Process Description - Core making and sand handling operations
are schematically illustrated in Figure 3.7.18. Cores are
used in the molds to form the interior of hollow castings.
The cores are prepared with binders, which usually require
baking to develop the strength required to resist erosion and
deformation when the mold is filled with molten metal. Several
types of core ovens are in use, including shelf ovens, drawer
ovens, portable-rack ovens, car ovens, and conveyor ovens.
Each type is more suitable for one application than another,
depending on such factors as maximum size or quantity of cores
that can be handled.
Inspection,
Shippinq
v
Charge — fe.
To Atmosphere
r-_ ,
Grindina ^
1 '*" Sh
r_. . -,
Furnace
t
1 1
1 1 . u 1 Tumble ,
i Bag House , ;
Pattern
Shop
Mold-Core
Bake
t
Core
Mold
Ovens
1
t-» and
1 Uan/< Thin 1
r i
>•
PouHnq
Room
'
Shop
Shop
Mullers
1
Bag House
1 — +•
Shake-Out
Room
' J
Rotary '° *
Screens
Hamner
Sand, Oil
Binders
' Mill
Sarjd
Figure 3.7.18 Core making and sand handling
3-149
-------
Atmospheric Emissions - Emissions from core making and sand
handling operations are usually much less significant than
those of other foundry operations. The core baking oven emissions
consist primarily of condensed and gaseous hydrocarbons. Emission
rates are highly variable, depending on binder composition and
baking procedures. Odor may be a problem. Emissions from the
sand handling system consist mainly of sand.
Control Systems - Emissions from core ovens can be controlled by
afterburners, although most ovens are not controlled. Emissions
from sand handling operations can be controlled by fabric filters.
Compliance Schedules - Figures 3.7.19 and 3.7.20 illustrate
expeditious schedules for installation of an afterburner or core
ovens and a baghouse on sand handling operations, respectively.
Sources of Additional Information
Type of
Source Information*
1. Air Pollution Engineering Manual P, E, C
Public Health Service Publication
No. 999-AP-40
2. Systems Analysis of Emissions and
Emissions Control in the Iron
Foundry Industry P, E, C
NTIS No. PB 198-348
3. Air Pollution Engineering Manual P, E, C
Public Health Service Publication
No. 999-AP-40
* P = Process description
E = Emission rates
C = Control devices
3-150
-------
Figure 3.7.19 Schedule for installation of an afterburner on
a core baking oven for hydrocarbon emissions control.
i
H
Ul
= Milestones
•• - Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
t-F
F-G
G-l
!-h
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and aporova!
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
OJ
I
M
U1
Figure 3.7.20 Schedule for installation of a fabric
filter on a sand handling system for
particulate pollutant control.
= Milestones
*• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency0
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipmento
4 Date by which on-site construction or installation of emission control equipment is completeda
5 Date by which final compliance is achieved u
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.8 Mineral Industries
3.8.1 Portland Cement
Process Description - Portland cement is manufactured by both dry
and wet processes. Both processes include four major steps:
quarrying and crushing, grinding and blending, clinker production
through calcination, and finished grinding and packaging.
In the wet process, the wet ground material is pumped in
slurry form to large mixing tanks, from which it is subsequently
pumped to the kilns. In the dry process, the dry, ground raw
material is conveyed to the storage bins and then fed to the
kilns. In the initial section of the kiln, the ground material
is heated and dried. As it progresses through the kiln it is
calcined and heated until it fuses, forming clinker. The clinker
is discharged from the kiln, cooled, and ground to produce the
finished cement.
A simplified flow diagram of cement plant operation is
shown in Figure 3.8.1.
Atmospheric Emissions - More than a dozen process areas in a
typical cement plant require effective emission control. These
processes encompass widely varying conditions of temperature,
dust load, air volumes, and particle sizes, and all require high-
efficiency collection systems.
3-153
-------
I
H
U1
"- —
1
*
TO
TRUCK,
BOX CAR
PACKAGING
MACHINE
RR CAR
Figure 3.8.1 Cement manufacture.
-------
The major source of particulate emission from both the dry
and wet processes is the calcining kiln. Dust is generated by
the tumbling action within the kiln as well as by volatilization
of components during calcination. Secondary in importance as
sources of particulate emission are the clinker cooler and the
grinders.
Particulate emissions from the calcining kiln range between
15 and 55 pounds per ton for the wet process, and 35 and 75 pounds
per ton for the dry process.
Control Systems - Both fabric filters and electrostatic precipi-
tators are used to control emissions from cement kilns. Fabric
filters are more commonly used on dry process systems because of
their higher collection efficiencies and relative insensitivity
to variations in process operating conditions; they are also used
occasionally on wet process sytems. Fabric filters are also used
to control emissions from various transferring and handling opera-
tions. Electrostatic precipitators are used primarily to control
emissions from kilns on wet process plants.
Compliance Schedules - Figures 3.8.2 and 3.8.3 illustrate expedi-
tious schedules for installation of a fabric filter and an electro-
static precipitator on a cement kiln.
3-155
-------
Sources of Additional Information
Type of
Source Information*
1) Atmospheric Emission from the P
Manufacture of Portland Cement.
Public Health Service Publication
No. 999-AP-17
2) Handbook of Emissions, Effluents, P,E,C
and Control Practices for
Stationary Particulate Pollution
Sources.
NTIS No. PB 203-522
3) A Manual of Electrostatic Precipi- C
tator Technology, Part II -
Application Areas.
NTIS No. PB 196-381
4) Background Information for Proposed C
New-Source Performance Standards:
Steam Generators, Incinerators,
Portland Cement Plants, Nitric Acid
Plants and Sulfuric Acid Plants
NTIS No. PB 202-459
5) Air Pollution Aspects of Emission E, C
Sources: Cement Manufacturing
NTIS No. PB 200-080
* P = Process description
E = Emission rates
C = Control devices
3-156
-------
oo
I
M
en
-J
Figure 3.8.2 Compliance schedule for installation
of a fabric filter on a cement kiln
for particulate pollutant control.
~ Milestones
•• - Activity and duration in weeks
MILESTONES
Da*e of submitral of final control plan to appropriate agency,
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Dote by which on-si'e construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary Investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup/ shakedown, preliminary source test
-------
I
H
Ul
00
Figure 3.8.3 Compliance schedule for installation of an
electrostatic precipitator on a cement kiln for
particulate pollutant control.
= Milestones
' - Activity and duration in weeks
MILESTONES
Date of submitfal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-s!te construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.8.2 Lime
Process Description - The principal raw materials for lime manu-
facture are calcium carbonate (limestone) or calcium-magnesium
carbonate (dolomite or dolomitic limestone). The limestone or
dolomite is heated in either vertical or horizontal kilns to
decompose the carbonate, releasing C02 and leaving calcium and
magnesium oxide as the products. During the heating process,
moisture and volatile organic matter are also driven off. Figure
3.8.4 illustrates the lime manufacturing process.
Atmospheric Emissions - The major source of particulate emission
is the calcining kiln. Emissions vary with the type of kiln and
composition of the limestone. Vertical kilns emit less than
rotary kilns because of the larger size of the limestone charged,
the lower gas velocities, and the smaller amount of attrition. In
rotary kilns, abrasion of limestone produces dust, which is
entrained by the high velocity combustion gases. Particulate
emission from a rotary kiln, if uncontrolled, is about 200 pounds
per ton of lime processed. Emissions from vertical kilns are
approximately 8 pounds per ton.
Control Systems - Most rotary kilns incorporate a settling chamber
or cyclone precleaner to remove coarse particles. Wet scrubbers
and fabric filters using glass or Nomex fabric are us'ed for high
efficiency particulate collection. Electrostatic precipitators
3-159
-------
Limestone and Dolomite
Primary crusher
Screening and classification
f
Secondary crushing
*
Screening and classification
6-8 in. limestone_
for vertical kilns
*-2* in.
— limestone for —*•
rotary kilns
>
Calcination
(rotary and vertical kilns)
• Fuel
By-product
lime
crrr
Pebble
qui
Crushing and
'pulverizing
jening
and lump
:klime
1
Max size V-Jj in.
o High-calcium 1 Dolomitic
- 1 quicklime
1 Ground and
Hydrator •« — Water
1
only
pulverized
lime
\ '
Pressure
hydrator
1
Milling
steam
High-calcium and dolomitic
normal hydrated lime
Dolomitic pressure
hydrated Nme
Figure 3.8.4 Manufacture of lime and limestone products
(Source: Kirk-Othmer. Encyclopedia of Chemical Technology)
3-160
-------
are also used, but not as frequently as fabric filters or wet
scrubbers.
Compliance Schedules - Figures 3.8.5 and 3.8.6 illustrate expedi-
tious schedules for installation of a wet scrubber and a fabric
filter on lime kilns.
Sources of Additional Information
Type of
Source Information*
1) Handbook of Emissions, Effluents, P,E
and Control Practices for
Stationary Particulate Pollution
Sources.
NTIS NO. PB 203-522
2) Study of Technical and Cost C
Information for Gas Cleaning in
the Lime and Secondary Non-Ferrous
Metallurgical Industries.
NTIS No. PB 198-137
* P = Process description
E = Emission rates
C = Control devices
3-161
-------
Figure 3.8.5 Schedule for installation of wet scrubber
on lime manufacturing operation for
particulate pollutant control.
co
i
M
O\
Ni
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-1
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
U>
I
I-1
a\
u>
Figure 3.8.6 Schedule for installation of fabric filter
on lime manufacturing operation
for particulate pollutant control.
= Milestones
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completedB
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares aSMfnbly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.8.3 Phosphate Rock
Proces s Description - Phosphate rock processing involves
beneficiating the ore to reduce impurities, drying to remove
moisture, and grinding to improve its reactivity during
subsequent processing steps, such as its reaction with sulfuric
acid to produce phosphoric acid. A simplified phosphate rock
processing operation is shown in Figure 3.8.7.
ffAOTKULAK).
V
MftTUML GAS Oft Fill OIL
WET
PHOSPHATE
ROCK
Figure 3.8.7 Phosphate rock processing.
Atmospheric Emissions - The major sources of particulate
emissions are the grinding and drying operation; open storage
piles can cause significant emissions of fugitive dust.
3-164
-------
Emissions from uncontrolled phosphate rock processing vary
from approximately 2 pounds per ton of rock for transfer and
conveying systems to 40 pounds per ton for open storage piles.
Drying and grinding operations emit 15 to 20 pounds per ton
of rock processed.
Control Systems - Fabric filters are the most commonly used
high-efficiency control devices, operating with collection
efficiencies in excess of 99 percent.
Compliance Schedules - Figure 3.8.8 illustrates an expeditious
schedule for installation of a fabric filter on phosphate rock
processing operations.
Sources of Additional Information
Type of
Source Information*
1) Handbook of Emissions, Effluents,
and Control Practices for Stationary
Particulate Pollution Sources. P, E, C
NTIS No. PB 203-522
2) Kirk-Othmer, Encyclopedia of Chemical
Technology (2nd Edition) P
Interscience Publishers
New York, New York
3) Air Pollution Control Field
Operations Manual P
APTD Publication No. 1164
* P = Process description
E = Emission rates
C = Control devices
3-165
-------
CO
I
H
cn
-------
3.8.4 Glass
Process Description - At a typical glass plant, glass sand, soda
ash, limestone, cullet (broken glass), and minor ingredients are
batch weighed, mixed, and charged to the glass furnace. In the
furnace, the dry mixture blends with the molten glass; the batch
is mixed for homogeneity and heat conditioned to eliminate stones.
The molten glass from the furnace is partially cooled and
worked on forming machines in a variety of methods including
pressing, drawing, rolling, casting, and blowing in molds. The
glass articles are immediately conveyed to gas fired or electri-
cally heated annealing ovens which heat-treat to remove strains
developed during molding.
A flow diagram of a soda-lime glass plant is shown in Figure
3.8.9.
Atmospheric Emissions - Particulates can be emitted during the
unloading and transferring of raw materials. Emissions from the
glass furnace, however, present the most serious problem. The
rate of particulate emission from the furnaces varies consider-
ably, depending upon the composition of the glass produced and on
the furnace design and operating conditions. Container glass and
plate glass, both soda-lime glasses, generally present less of an
if?
-------
.
5IIK.A 1AND
W Va, lit. Mo; ar«
crujfiM, imf>»d.
apprp* PO-100 rnfih
-—. .
-—. .
SODA ASH
Na,CO,
to yetd todj, Ni,0
Appro* 20 120 meih
or granular
^_^-^
LIMESTONE
Or burnt lim«
to yeld Mm?, CaO
MgO also results
contains MgCOj
Approx 20-120 mesh
FELDSPAR
R, 0 M,0, 6SOZ
to yfkt alumina, Al,0,.
Also yields S'Oj,
and NijO or KZ0
Pulverized or granular
Borax or bone acid
to yield B,Qj, and
o'her additions to
yeid K20. MgO,
ZnO, 8aO. and P&O
F'fi'ng, oxidizing.
decolorizing and
coto'tng agenls
Materials dry, or nearly dry
Continuous tank furnace looking
down through top (crown)
Submersed throat m bndgewall
At about 1 . 472 . 2 . 0 I 2 F
depending on article and process
Melting
about 2 . 70o°>
Refining
fining and
homogemimg
Fabrication
Hot, viscous liquid glass
shaped by pressing,
blowing, pressing and
jlowing, drawing, or rolling
Figure 3.8.9 Soda-lime glass manufacture.
emission problem than specialty glasses. Particulate emissions
result both from entrainment of batch constituents in the
combustion air and from vaporization of certain volatile com-
ponents in the melt. The volatile constituents subsequently
condense to form particulates. Sulfates, fluorides, and borates
are common batch constituents causing volatilization. The great
3-168
-------
variety of compounds used to produce the hundreds of specialty
glasses can create substantial emissions problems, including the
potential for emitting hazardous air pollutants.
Emissions from container-glass forming operations are due
to the volatilization of the mold coating compounds, which
creates a constant haze in the vicinity of the glass forming
machine. Emissions from annealing ovens are negligible.
Control Systems - Fugitive dust emissions from unloading of raw
materials can be effectively controlled by use of choked feeding
and proper enclosures. Vent filters can be used on bin filling
and conveying operations. Fabric filters can be used on mixers
and weigh hoppers.
Only a few continuously operating control devices are used
on glass furnaces. The most acceptable systems currently used
are fabric filters and wet scrubbers. High-energy venturi
scrubbers are capable of 95 plus percent collection efficiency
but require pressure drop of approximately 50 inches of water.
Baghouses have shown particulate collection efficiencies
higher than 99 percent, but bag failures due to acid gases and
high temperatures are a problem. On tableware and opal glass
furnaces, fabric filters have proved effective.
3-169
-------
Wherever possible, many soda-lime glass plants are changing
batch compositions to reduce emissions and comply with emission
regulations. Volatilized emissions are lowered by elimination
or reduction of various refining agents such as sulfates. Also,
the fluoride content of the batch in many plants has been reduced
or eliminated to minimize fluoride emissions.
Electric furnaces offer a much lower emissions potential
than gas-or oil-fired furnaces. Several plants have replaced
existing furnaces with electric furnaces to meet emission regu-
lations; however, use of electric furnaces in lieu of installing
control devices is limited to those facilities where the annualized
operating costs would make this economically feasible and the
batch composition is such that emissions would be reduced suffi-
ciently to meet emission regulations.
Compliance Schedules - Figures 3.8.10 and 3.8.11 illustrate
expeditious schedules for installation of a fabric filter and a
high-energy venturi scrubber. Because of the limited operating
experience of these control devices on glass furnaces, these
schedules should be considered as only rough guidelines.
3-170
-------
Figure 3.8.10 Schedule for installation of a custom-designed
fabric filter on a glass furnace for
particulate pollutant control.
\0
U)
I
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
JSA.
-------
Figure 3.8.11 Schedule for installation of high-energy
venturi scrubber on glass furnace
for particulate pollutant control.
OJ
i
N)
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Milestones
Activity and duration in weeks
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME fWEEKS)
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Sources of Additional Information
Type of
Source Information*
I) Air Pollution Engineering Manual. P,E,C
PHS Publication No. 999-AP-40
2) Stockham, John D. The Composition E
of Glass Furnace Emissions.
Journal of the Air Pollution Control
Association, November 1971
Vol. 1, No. 11, page 713-715
3) Kirk-Othmer, Encyclopedia of Chemical P
Technology, Vol. 10, 2nd Ed., 1966
* P = Process description
E = Emission rates
C = Control devices
3-173
-------
3.8.5 Fiber Glass
Process Description - The manufacture of fiber glass consists of
melting various raw materials to form molten glass, drawing the
glass into fibers, and coating the fibers with an organic
material (the binder).
The processes, emissions, and control methods for the raw
material handling operations and the glass melting furnace are
similar to those described in Section 3.8.4.
Glass wool is formed by feeding molten glass through
platinum bushings to form fine fibers. The fibers are sprayed
with binders, cured at 400 to 500°F, air-cooled, and cut to
proper size. Figure 3.8.12 illustrates the overall operation.
Melting tank 100
.iin ig iaim i w -.
tons of glass /
Sievehke platinum bushings
.High-pressure steam jets
attenuate molten streams
into fine fibers
Drying oven
Fiber deposited on conveyor
Figure 3.8,12 Fiber glass production
(Source: Kirk-Othmer. Encyclopedia of
Chemical Technology)
3-174
-------
Atmospheric Emissions - The spraying resins on the glass fiber
in the forming operation create a substantial volatile emissions
problem. Components in the resin are driven off when contacting
the hot fibers and subsequently condense to form fine particu-
lates. The emission rate is increased by use of very fine binder
sprays and binders with a high percentage of volatile components.
The curing ovens also emit volatile components from the
binder, which condense upon cooling to create visible emissions.
Oven temperature and binder composition affect the emission rate.
Control Systems - The High-Energy Air Filter device (HEAP) is the
most widely used emission control method for forming lines and
curing ovens. The unit usually requires pressure drops in excess
of 30 inches water gauge to operate satisfactorily. High-energy
wet scrubbers and afterburners have also been used to control
emissions.
Compliance Schedules - Figures 3.8.13, 3.8.14, and 3.8.15 illus-
trate expeditious schedules for installation of a high-energy wet
scrubber, a HEAP unit, and an afterburner on forming line and
curing oven emission sources.
3-175
-------
OJ
I
Figure 3.8.13 Schedule for installation of a high-energy wet scrubber
on fiber glass forming and curing operations
for particulate pollutant control.
- Milestones
-* - Activity and duration In weeks
MILESTONES
Date of submirtal of final control plan to appropriate agency,,
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved..
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C Preliminary investigation
A-B Source tests
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare preliminary control plan and compliance
schedule for agency
F-G Agency review and approval
G-l Finalize plans and specifications
1-H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.8.14 Schedule for installation of a high-energy air filter
(HEAP) unit on fiber glass forming and curing operations
for particulate pollutant control.
-LI
OJ
I
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
J9JSL
-------
Figure 3.8.15 Schedule for installation of an afterburner
on fiber glass forming and curing operations
for particulate pollutant control.
oo
I
I-1
^J
00
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
ELAPSED TIME (WEEKS)
Dote of submitted of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-------
Sources of Additional Information
Type of
Source Information*
1) Kirk-Othmer, Encyclopedia of P
Chemical Technology.
Vol. 10, 2nd Ed. 1966
2) Air Pollution Engineering P,E,C
Manual.
PHS Publication No. 999-AP-40
* P = Process description
E = Emission rates
C = Control devices
3-179
-------
3.8.6 Asphalt Batching
Process Description - Asphalt batch processing consists of
drying and heating various aggregates, screening, proportioning,
weighing, and then mixing the hot dry aggregate with molten
asphalt. Both continuous and batch mix plants are in operation.
These plants are very similar except for the final weighing
and mixing steps, which in the latter case is done on a batch
basis. Asphalt batch plants range in size between 50 and 300
tons per hour.
As shown in Figure 3.8.16, aggregate consisting of crushed
stone, slag, and gravel or sand is sized and loaded in a
storage hopper. From the hopper it flows into the elevated
end of a rotary dryer. A gas or oil burner supplies heat
directly at the lower or discharge end of the dryer. After
drying, the hot aggregate is screened and mixed with hot asphalt,
Atmospheric Emissions - Conveyor belt and bucket elevator
transfer points, bin loading, and screening operations can be
sources of fugitive dust emission. The combustion gas stream
from the rotary dryer, however, is the primary source of
particulate emissions. This stream usually passes through a
cyclone precleaner to remove some particulate, but emissions
3-180
-------
still amount to about 5 pounds per ton of product. The
particulate emission rate increases as the particle size of
the aggregate decreases.
PAKTICUUkTE (MISSION POINTS
ASPHALTC Oil (HOT) ROM
TANKCAI OK THICK
(L
r
STACK
(TO AIMOSPHEK)
COAL, GAS
""•otoa
STEAM JACKETED ASPHALT 1C
Oil TANK
Figure 3.8.16 Asphalt batch plant.
Control Systems - Covering belt conveyors, elevators, screens,
bins and other handling operations, and venting the displaced
air through a fabric filter system will effectively control
emissions from these sources.
3-181
-------
A cyclone precleaner, followed by a fabric filter or
high-energy wet scrubber can be used to reduce particulate
emissions from the rotary dryer. Scrubber systems should
provide at least 10 gallons of water per 1000 standard cubic
feet of exhaust gas. Pressure drops through the scrubber
should be in the range of 10 to 20 inches of water. Fabric
filter systems commonly use glass fiber or Nomex fabric and
2
operate at air-to-cloth ratios of 3.5 to 6.5 (CFM per ft ).
Compliance Schedules - Figures 3.8.17 and 3.8.18 respectively
illustrate expeditious schedules for installation of a wet
scrubber and a fabric filter on a rotary kiln.
Because of the seasonal nature of the industry in the
northern climates, field construction and control system tie-in
are sometimes scheduled only during the winter and early
spring to avoid financial hardships.
Sources of Additional Information
Type of
Source Information*
1) Air Pollution Engineering Manual P, E, C
PHS Publication No. 999-AP-40
2) Handbook of Emissions, Effluents, and
Control Practices for Stationary
Particulate Pollutant Sources P, E, C
NTIS No: PB 203-522
* P = Process description
E = Emission rates
C = Control devices
3-182
-------
OJ
I
00
Figure 3.8.17 Schedule for installation of a wet
scrubber on an asphalt batch plant
for particulate pollutant control.
= Milestones
*" = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agency*
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Deiiqnction
A-C
A-B
C-D
D-E
e-f
F-G
G-1
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-f\l On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.8.18 Schedule for installation of a fabric
filter on an asphalt batch plant
for particulate pollutant control.
U)
i
00
= Milestones
^ = Activity and duration In weeks
MILESTONES
1 Date of submlfrtal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment,
4 Date by which on-site construcfion or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Desi.-^nction
A-C
A-S
C-D
D-E
E-f
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawing*
Designation
K-l Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.8.7 Asphalt Roofing
Process Description - Asphalt roofings are made by impregnating
a felt base with asphalt on high-speed, continuous machines,
called asphalt saturators. Figure 3.8.19 schematically illus-
trates this process. The felt is fed continuously from rolls
onto the dry looper, which provides live storage of felt so
that changing rools will not interrupt production. From the
dry looper, the felt travels to the spray section, where
liquid asphalt heated to 400 to 450°F is sprayed on one side
of the felt; this spraying drives the moisture out of the
unsprayed side and prevents blisters when the felt is saturated.
In the asphalt tank, the felt is impregnated with asphalt
maintained at the desired temperature by continuous circulation
through an asphalt heater. The impregnated felt then enters
the wet looper, where it is cooled by traveling over sets of
rollers arranged in long vertical loops. The impregnated felt
is rolled at the discharge end of the wet looper for use as
roofing felt; or rock granules, or other materials can be added
and the felt cut for use as roofing shingles.
At some roofing plants, the asphalt saturant must first
be processed. This preparation, called "blowing", consists of
oxidizing the asphalt by bubbling air through it for 8 to 16
hours.
3-185
-------
TO
rouunoN CONTHOI
(QUIfMCNT
ASfHAlT
SATUMMT
IO
ASPHALT
HEATH
Figure 3.8.19 Manufacture of asphalt roofing materials.
Atmospheric Emissions - The relatively high temperature at
which the asphalt is applied to the felt causes the lower-
boiling-point components of the asphalt to vaporize. In
addition, moisture in the felt vaporizes, resulting in steam
distillation of the asphalt. The vaporized components
subsequently condense as very fine particulate matter and
create a highly visible plume. Emissions from the asphalt
saturation operation without controls range from 1 to 3 pounds
of particulate matter per ton of saturated felt produced.
3-186
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The asphalt blowing operation is another significant
source of air pollution. Uncontrolled emissions are approxi-
mately 2.5 pounds and 1.5 pounds of particulate and hydrocarbons,
respectively, per ton of saturated felt produced.
Control Systems - A common method of control at asphalt
saturating plants is the complete enclosure of the spray and
saturator area, with ventilation through one or more control
devices.
The two most effective control devices are direct-flame
afterburners and high-energy air filters (HEAP). The latter
is a disposable, once-through, moving filter pad of glass
fiber through which the process exhausts pass. Generally,
HEAF units are used on existing plants where heat recovery is
not practical. Most new installations utilize afterburners
with heat-recovery systems.
Compliance Schedules - Figures 3.8.20 and 3.8.21 illustrate
expeditious schedules for installation of a direct-fired after-
burner and a high-energy air filter, respectively.
Sources of Additional Information
Type of
Source Information*
1) Air Pollution Engineering Manual P, E, C
PHS Publication No. 999-AP-40
* P = Process description
E = Emission rates
C = Control devices
3-187
-------
Figure 3.8.20 Schedule for installation of an afterburner
on an asphalt roofing operation
for particulate pollutant control.
co
I
H
00
00
= Milestones
*• - Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
OJ
I
H
00
Figure 3.8.21 Schedule for installation of a HEAP
unit on asphalt roofing operation
for particulate pollutant control.
- Milestones
• - Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agencyt
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
IP
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.8.8 Concrete Batching
Process Description - Three types of concrete batching plants
are in use: wet-batch plantsr central mix plants, and to a much
lesser extent, dry-mix plants. In wet-batch plants, sand, aggre-
gates, and cement are mixed in proper proportions and dropped into
a transit-mix truck. Water is added simultaneously, as shown in
Figure 3.8.22.
•HEIGH HOPPERS-
X
GATHERING
HOPPER
COMPRESSED-AIR
CYLINDERS
METAL PLATE
FOAM RUBBER
TRANSIT-MIX
TRUCK
Figure 3.8.22 Wet-concrete batch loading operation
3-190
-------
In central mix plants, the raw materials are mixed at a
central plant and wet concrete is delivered to the job site in
open trucks. In dry-mix plants, sand, aggregate and cement are
mixed dry; water is added and the concrete is mixed at the job
site.
Atmospheric Emissions - Particulates can be emitted in signifi-
cant quantities from receiving and conveying of cement, sand, and
aggregates, and from load-out of the concrete. Factors affecting
the emission rate include the amount and particle size of the
materials handled, and the type of handling systems used.
Particulate emissions from an uncontrolled wet-batch plant are
approximately 0.2 pound per cubic yard of concrete. Dry-mix
plants have a much higher emission potential.
Control Methods - Enclosure of dumping areas and of conveyors and
elevators, together with the use of bin vent filters will substan-
tially reduce particulate emissions. Wet scrubbers have encountered
operational difficulties such as plugged spray nozzles, corrosion,
and waste-water disposal problems.
Compliance Schedules - Figure 3.8.23 illustrates an expeditious
schedule for installation of a fabric filter on a concrete batch
plant.
3-191
-------
Figure 3.8.23 Schedule for installation of a fabric
filter on a concrete batch plant
for particulate pollutant control.
OJ
i
= Milestones
*" - Activity and duration in weeks
MILESTONES
Date of submittai of final control plan to appropriate agencyD
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construcfion or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
1
2
3
4
5
ACTIVITIES
Designation
A-C Preliminary investigation
A-B Source tests
C-D Evaluate control alternatives
D-E Commit funds for total program
E-F Prepare preliminary control plan and compliance
schedule for agency
F-G Agency review and approval
G-l Finalize plans and specifications
1 -H Procure control device bids
H-J Evaluate control device bids
J-2 Award control device contract
2-K Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Sources of Additional Information
Type of
Source Information*
1) Air Pollution Engineering Manual P,E,C
PHS Publication No. 999-AP-40
2) Exhaust Gases from Combustion P,C
and Industrial Processes
NTIS Publication No. PB 204-861
* P = Process description
E = Emission rates
C = Control devices
3-193
-------
3.9 Petroleum Industry
3.9.1 Petroleum Refining
Process Description - Petroleum refineries normally range in
size from 20,000 barrels per day or less to 200,000 barrels
per day or more for a complete modern refinery.
Crude oil is initially separated by distillation into
boiling range fractions (e.g., gas, naphtha, kerosene, middle
distillates, and heavy bottoms). Since these fractions
seldom conform to either product demand or quality requirements,
the less desirable fractions are converted to more marketable
products. This conversion normally consists of splitting,
uniting, or rearranging the original molecular structure.
The subsequent separation and conversion products are then
treated for removal of undesirable components, and blended with
each other and a variety of additives to meet product speci-
fications .
The conversion processes consist of hydro-, catalytic-,
and thermal-cracking which function principally to produce
smaller, lower-boiling-point hydrocarbons. Catalytic reforming
produces higher quality gasoline mainly by isomerizing and
aromatizing naphtha. Polymerization combines two or more
3-194
-------
gaseous olefins, while alkylation combines an olefin with an
isoparaffin to form gasoline range hydrocarbons. An isomerization
unit is used to increase molecular branch chain formation and
increase gasoline quality. The most common treating processes,
such as caustic treating, hydrotreating, and desulfurization
are used to reduce the product's sulfur content.
Figures 3.9.1 and 3.9.2 illustrate processing plans for
intermediate and complete refineries, respectively.
Atmospheric Emissions - Refinery operations entail a number of
emission sources, including storage tanks, waste-water sewer
systems, pumping systems, blowdown systems, boilers and process
heaters, and catalytic regeneration units. Emissions from
many of these sources can be effectively controlled by proper
design and maintenance.
Storage tanks are significant potential sources of hydro-
carbon emissions, particularly those storing crude oil and
light distillates. Vapor is lost mainly from direct evaporation
and displacement during filling. Hydrocarbon losses can be
minimized by the use of pressure tanks, vapor-recovery systems,
or floating-roof tanks, as described in Section 3.3.2.
The waste-water sewer system can also cause significant
hydrocarbon emissions unless it is properly designed and
3-195
-------
Wet gas
Crude oil
Amosphenc topping unit
Straight run
naphtha
Heavy naphtha
Raw kerosme
Middle disti
Heavy gas
I
Gas planl
1
^IAI
Catalytic reformer ,,
r
late 1 ^ Hydrotreating plant
oil
lc
i
Catalytic cracker
c gas oil
Cracked c
Light fu
1 Aikylate
lotion \ — —- V
' SR gasoline
r
Reformate
•o
0)
6 +-
L
o> o
S Q-
3
-.»_ Fuel gas
•- H'
-------
maintained. The front end of the waste-water gravity separator
can be covered. Catch basin liquid seals, manhole covers, and
other good housekeeping practices;will reduce drainage system
vapor losses.
The complex network of piping and valves is a large
potential source of hydrocarbon emissions but can be controlled
by good maintenance practices. Hydrocarbon emissions from
pumps and compressors can be reduced by proper maintenance and
the use of mechanical seals in light hydrocarbon service.
Blowdown systems, which are used during startups and shut-
downs of process units to vent hydrocarbon vapors and during
routine operation to capture various hydrocarbon leaks and .
relief valve venting, are designed to recover condensable
hydrocarbons and flare the non-condensibles. Emissions can be
minimized by utilizing a properly designed steam or air injection
smokeless flare.
Boiler and process heaters using heavy fuel oil are a
major source of particulates, nitrogen oxides, and sulfur
oxides. Significant quantities of hydrocarbons and aldehydes
can also be emitted.
The catalyst regeneration system of the catalytic-cracking
unit is a major source of carbon monoxide, sulfur and nitrogen
oxides, hydrocarbons, and particulate emissions. In the Fluid
3-197
-------
Catalytic Cracking Unit, the most common type used in larger
refineries, the catalyst is regenerated in a continuous moving
bed to maintain unit heat balance and burn off coke formed on
the catalyst surface.
Regeneration of fixed bed reforming, hydrotreating and
hydrocracking catalyst is normally done in batch during a shut-
down. The regeneration consists of burning coke and other
deposits off the catalyst with a circulating inert gas stream
containing a controlled oxygen content. Regeneration of
reforming catalyst emits CO2 and some halides as acid mist.
The regeneration of hydrotreating and hydrocracking catalyst
emits CO_, S0_, ammonia, and other minor impurities.
Control Systems - As mentioned earlier, many emissions may be
effectively reduced by proper maintenance or by venting to a
vapor recovery or flare system.
Sulfur-laden hydrocarbon vapor streams are normally
treated by amine treaters, which yield a recoverable hydro-
carbon stream and a stream high in H»S. Vapor streams rich in
H2S can be controlled by a sulfur plant (Claus Unit) which
recovers elemental sulfur; Claus plant sulfur removal effi-
ciencies are approximately 93 to 99 percent. Several processes
are available to reduce the sulfur content of the tail gas
3-198
-------
from a Glaus Unit, some of which process the tail gas before
incineration and some after incineration. The product stream
is either elemental sulfur or S0«. Among the processes available
that appear acceptable are the Beavon Sulfur Removal Process,
the Clean Air Sulfur Process, the Shell Flue Gas Desulfurization
Process, and the Wellman-Power Gas S02 Recovery Process.
Carbon monoxide and hydrocarbon emissions from a Fluid
Catalytic Cracking Unit can be controlled by waste heat boilers,
and particulate emissions by electrostatic precipitators. Waste
heat boilers are normally used on all large units for heat
recovery. Multi-stage cyclones, which are an integral part of
the cracking unit, will also reduce the particulate load to the
precipitator.
Emissions from fixed bed catalyst regeneration can be
controlled by passing regeneration gases through a caustic
scrubber and venting the wet gas to a fire box.
Compliance Schedules - Figures 3.9.3, 3.9.4, 3.9.5, and 3.9.6
illustrate expeditious schedules for installation of an amine
treater-sulfur plant,a tail gas desulfurization unit, a package
amine treater-sulfur plant and tail gas desulfurization plant,
and an electrostatic precipitator, respectively. For tail gas
desulfurization, the schedule represents an average time require-
ment for the several processes available.
3-199
-------
Sources of Additional Informati
on
Type of
Source Information*
1) Air Pollution Engineering Manual P, E, C
PHS Publication No. 999-AP-40
2) Air Pollution, A.C. Stern, Vol. Ill
Chapter 34 - Petroleum Refinery
Emissions, Academic Press, 1968 P, C
3) Petroleum Refinery Engineering P, C
W.L. Nelson, McGraw-Hill 1958
4) Atmospheric Emissions from Petroleum E
Refineries - A Guide for Measurement
and Control
NTIS No. PB 198-096
* P = Process description
E = Emission rates
C = Control devices
3-200
-------
Figure 3.9.3 Schedule for installation of an amine-treater-
sulfur plant for hydrogen sulfide emission control.
J
4
0
u>
i
to
o
MILESTONES
1
2
3
4
5
ACTIVITIES •
DESIGNATIONS
1 -2
2-3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Dote of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing .
-4-
faff
-------
Figure 3.9.4 Schedule for installation of a tail gas
desulfurization unit for sulfur
oxide emissions control.
JLZ
M-
ax>
U)
I
ro
o
to
MILESTONES
1
2
3
4
5
ACTIVITIES '
DESIGNATIONS
1 -2
1 -3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site.
Delivery of remaining equipment and completion of construction including process tie in,
Equipment start up and source testing .
TQ
-------
Figure 3.9.5 Schedule for installation of an amine
treater, a sulfur plant and a tail-
gas desulfurization unit.
•s
i
NJ
o
oo
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2-3
3-4
4-5
ELAPSED TIME (WEEKS)
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved.
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site .
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-JHL
JZL
-------
I
to
o
Figure 3.9.6 Schedule for installation of an
electrostatic precipitator
for particulate pollutant control.
- Activity and duration in weeks
MILESTONES
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-sife construction or installation of emission control equipment.
Date by which on-sife construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3 .10 Pulp and Paper
3.10.1 Kraft Process
Process Description - The Kraft Process, shown schematically
in Figure 3.10.1, uses an aqueous solution of sodium hydroxide
or sodium hydroxide and sodium sulfide to dissolve the lignin
binding the wood fibers. This solution, the "white liquor",
is mixed with wood chips in a large pressure vessel, the
digester, and cooked for several hours with steam.
When the cooking is completed, the contents of the
digester are forced into a blow tank. The pulp is then
separated from the spent black liquor, washed in several
stages, and bleached before it is sent to the paper mill for
further processing.
The spent "black" liquor together with the water from
the pulp washer is initially concentrated in a multiple effect
evaporator. It is usually further concentrated by direct
contact evaporation with the flue gas from the recovery boiler,
The combustible, concentrated black liquor from the direct
contact evaporator is injected into the recovery boiler and
burned. Heat is recovered in the form of steam and the
inorganic chemicals in the spent liquor fall to the floor
of the furnace in a molten state.
3-205
-------
WOOD CHIPS
RELIEF
GASES
00
1
NJ
O
FRESH
MAKE UP
LIQUOR
DIRECT
CONTACT
EVAPORATOR
MULTIPLE
EFFECT
EVAPORATOR
WATER
Figure 3.10.1 Kraft Process
-------
The resulting melt, which consists essentially of a mixture
of sodium sulfide and sodium carbonate, is withdrawn from the
furnace and dissolved in water and weak liquor from the
causticizing plant. The "green" liquor thus produced is
further treated with calcium hydroxide to convert the sodium
carbonate to sodium hydroxide. The calcium carbonate pre-
cipitates from the solution and is collected and sent to the
lime kiln. There it is calcined to calcium oxide, which is
slaked and converted back to calcium hydroxide. This treatment
of the "green" liquor produces the "white" cooking liquor used
in the digester.
Atmospheric Emissions - The major sources of particulate emission
from the Kraft pulp mill, in decreasing order of importance, are
1) the recovery furnace, 2) the lime kiln and 3) the smelt
dissolving tank.
It is estimated that 150 pounds of particulates would be
emitted from an uncontrolled recovery furnace for every ton
of air-dried pulp produced. The corresponding figures for the
lime kiln and the smelt dissolving tank are 45 pounds per ADT
and 2 pounds per ADT, respectively.
Odors can be a serious emission problem especially if
direct contact evaporation is used or the recovery boiler is
3-207
-------
improperly operated. Sulfur oxides can also be emitted from
the recovery boiler.
Control Systems - Electrostatic precipitators are commonly
used to control emissions from recovery furnaces, and wet
scrubbers to control emissions from lime kilns and smelt
dissolving tanks.
Compliance Schedules - Figures 3.10.2 and 3.10.3, respectively,
illustrate expeditious schedules for installation of an electro-
static precipitator and a wet scrubber for particulate emission
control.
Sources of Additional Information
Type of
Source Information
1) Handbook of Emissions, Effluents,
and Control Practices for Stationary
Particulate Pollution Sources P, E, C
NTIS No. PB 203-522
2) A Manual of Electrostatic
Precipitator Technology, Part II -
Application Areas/ NTIS No. PB 196-381 C
3) Encyclopedia of Chemical Technology P
Kirk-Othmer, Vol. 16, 2nd Edition
4) Control of Atmospheric Emissions in
the Wood Pulping Industry
NTIS No. PB 190-351, 342, 353 P, E, C
* P = Process description
E = Emission rates
C = Control devices
3-208
-------
Figure 3.10.2 Schedule for installation of an electrostatic
precipitator on recovery boiler in pulp
mill for particulate pollutant control.
00
I
NJ
O
= Milestones
*• - Activity and duration in weeks
MILESTONES
1 Date of submitfal of final control plan to appropriate agency.
2 Date of award of control device contract.
3 Dote of initiation of on-sife construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Dote by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P~Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Figure 3.10.3 Schedule for installation of a wet scrubber on
lime kiln and smelt dissolving tank in a Kraft mill
for particulate pollutant control.
CO
i
NJ
= Milestones
•• - Activity and duration in weeks
MILESTONES
1
2
3
4
5
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-f
F-G
G-l
1-H
H-J
J-2
2-K
Date of submirtal of final control plan to appropriate agency .
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction or installation of emission control equipment is completed.
Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
2
\0
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
3.10.2 Sulfite Pulping
Process Description - Pulp mills operating with acid cooking
liquor and having no recovery system for spent liquor pose a
problem of water rather than air pollution. Restrictions on
the discharge of the spent liquor to surface waters will make
mandatory the installation of spent recovery systems at those
plants that have not already installed such a system. However,
in treating the water pollution problem an air pollution problem
is created. For this reason a control system designed for water
treatment also must include air pollution control.
The several commercial systems for treatment of spent sulfite
liquor follow basically the same steps: 1) concentration of the
dilute spent liquor to a point where it can sustain combustion;
2) burning of the concentrate and recovery of the base chemical
and heat; and 3) flue gas quenching and control of sulfur dioxide
by scrubbing the gas with a solution containing the recovered
base chemical. A simplified flow diagram of the process is shown
in Figure 3.10.4.
Dilute spent sulfite liquor from the pulp washer is sent to
a multiple effect evaporator where water is driven off and the
liquor is concentrated to about 50 percent solids. Some volatile
hydrocarbons, such as acetic acid, are also driven off and leave
the evaporators with the condensate to water treatment system for
BOD/COD reduction. The concentrated liquor is combusted in the
primary recovery furnace, and steam is generated from the heat
of combustion. The recoverable chemical base, such as magnesium,
3-211
-------
STEAM
STACK
BOILER FEED WATER
I
NJ
H
NJ
SPENT SULFITE
LIOUCR FROM
PULP WASHER
MULTIPLE
EFFECT
EVAPORATOR
PRIMARY
RECOVERY
FURNACE
BASE CHEMICAL MAKE UP
WATER
SC2
MAKE UP
COOKING
LIQUOR
TO DIGESTER
CONDENSATE TO SECONDARY
WATER TREATMENT SYSTEM
WASH WATER
TO SEWER
Figure 3.10.4 Spent sulfite liquor recovery system.
-------
is collected through a multi-cyclone dry collector or an electro-
static precipitator. If the base is not recoverable, as with
ammonia, then no ash collector is needed, since the ammonia is
also combusted in the furnace and emitted as nitrogen and N0x
compounds.•• The recoverable base, in the form of an oxide, is
washed to remove soluble impurities such as the sulfates, then
slaked to form the hydroxide, which is then used as the chemical
base in the SO- secondary recovery system to scrub the SO., from
the gas and form a weak sulfite liquor. This weak liquor
is fortified by injection of SO- under low pressure to form rich
cooking liquor, which is sent back to the digester.
The gases from the secondary system leave the stack as
essentially inerts and moisture, with traces of S02 and N0x«
A poorly designed or improperly operated spent liquor
recovery system can be a source of air pollution.
Compliance Schedules - A compliance schedule for construction and
startup of a properly designed spent liquor recovery system is
shown in Figure 3.10.5. The duration of this compliance schedule
should be sufficient for the simultaneous installation of any
associated water treatment system that may be required for BOD
reduction.
3-213
-------
Figure 3.10.5 Schedule for installation of a spent sulfite
liquor recovery system in a pulp mill.
Ifo
>Q
CO
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2 -3
3 -4
4-5
Date of submittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved .
ELAPSED TIME (WEEKS)
\
-------
4.0 SUPPORTING DATA
4.1 Vendor Data
4.1.1 Quoted Delivery Schedules
Nine major manufacturers of air pollution control equipment
were contacted to provide information on the time required for
design and fabrication of control devices. Except for install-
ation of electrostatic precipitators, manufacturers agreed
substantially with regard to quoted schedules. Electrostatic
precipitators require the longest delivery times, and variation
among suppliers' schedules is significant. A relatively small
number of recognized firms sell precipitators, and the market is
dominated by a few major manufacturers; this situation stems
from the complexity of electrostatic precipitator design.
Data obtained from vendors are summarized by control device
type in the following sections.
Electrostatic Precipitators - Schedules for activities
in the fabrication and installation of electrostatic precipitators,
obtained from seven precipitator manufacturers, are presented in
Table 4.1. Data provided by vendors (A) and (G) were disregarded
as being out of line with those provided by the other vendors;
since these vendors command a small share of the precipitator
market, schedules based on their figures would not provide proper
guidelines for evaluating compliance schedules submitted for
most emission sources.
4-1
-------
Table 4.1 VENDOR DELIVERY SCHEDULES FOR ELECTROSTATIC PRECIPITATORS
Vendor
A
A
B
B
C
C
D
D
E
E
F
F
G
Equip. Size, CFM
<200,000
>200,000
<100,000
>100,000
Small
350,000
<100,000
>100,000
Small
Large
Small
~100,000
100,000-500,000
Assembly
Drawings
4-6 Wks
4-6
3
3
Fabrication
Drawings
10-14 Wks
10-14
12
12
12
12
12
12
6-8
6-8
4-5
2-4
Initial Delivery
To Construction Site
10 Wks
14 Wks.
40
52
27-36
27-36
12-16
12-16
42
42
36
14-16
Completion of Construction
Since Initial Delivery
8 Wks
12
Wks
Wks
13
13
12-20
12-20
3
3
10-12
12
Debugging
2 Wks
2
3
4
6
6
2
2
2
2
2 Wks.
Testing
4 Wks
4
9-18
12-24
2
2
2
2
-------
Table 4.2 VENDOR DELIVERY SCHEDULES FOR FABRIC FILTERS
I
CO
Vendor
A
A
B
C
C
D
E
Equip. Size, CFM
<150,000
>150,000
<50,000
<200,000
>200,000
100,000
(modular)
>100,000
Assembly
Drawings
4-6 Wks
4-6 Wks
Fabrication
Drawings
2 Wks
2
4
6
10-14
10-14
2-4
4
Initial Delivery
To Construction Site
10-14 Wks
^xl8
4
10
10
14
8-10
14-16
12-14
Completion of Construction
Since Initial Delivery
1-2 Wks
^3
1
2
8
12
2-12
10-12
Debugging
1-2 Wks
2
1
2
2
2
Testing
1 Wk
1
4
4
-------
The average time for fabrication and construction of small
electrostatic precipitators is about 37 weeks. Average time for
larger units is about 46 weeks. These values represent conditions
in the first quarter of 1973. As demand increases the elapsed
time may also increase, but considerable variation among manu-
facturers would still be expected. Thus the expeditious schedules
would still be reasonable, although the purchaser might have to
contact more than one precipitator vendor to meet such a schedule.
Fabric Filters - Six vendors provided fabrication and con-
struction times for fabric filters. Except for Vendor B, these
figures are more consistent than those obtained for electrostatic
precipitators. Construction time for fabric filters is about
18 weeks for small units and about 24 weeks for large units.
Table 4.2 summarizes data provided by the vendors.
Wet Scrubbers - Schedules for delivery and construction of
wet scrubbers, obtained from six vendors, are tabulated in
Table 4.3. Since high-pressure fans on some installations could
require long delivery time, several fan manufacturers were also
contacted. Data obtained from these manufacturers are summarized
in Table 4.4.
Excluding the data from Vendors A and B for small wet
scrubbers, the average time for fabrication and erection of small
4-4
-------
TABLE 4.3 VENDOR DELIVERY SCHEDULES FOR WET SCRUBBERS
Vendor
A
B
B
C
C
D
D
E
E
F
F
Equip. Size, CFM
<50,000
Small
Large
<80,000
>80,000
xv 100, 000
Large
x^-100,000
Large
Assembly
Drawings
Fabrication
Drawings
4-5 .Wks.
2-4
4-8 (Hi-Ene
4
6
4
4-6
Equip. Delivery
7 V
7-1
rgy) 20-:
Equip. Erection
ks.
1
4
14-16
16-20
Vulcanized) 20 Wks. --XL Wk.
Rubber f
Lined I 30
14-16 Wks.
14-16 Wks.
10-14 Wks.
/^2
3
3
Debugging
1-2 Wks.
2-4
2
2
Testing
1-2 Wks.
2-4
-------
TAble 4.4 VENDOR DELIVERY SCHEDULES FOR HIGH-PRESSURE FANS
I
en
Vendor
A
A
B
C
C
D
P
Equip. Size, CFM
<40,000 &<15"SP
>40,000 &>15"SP
>20,000 &>20"SP
:100,000 &<24"SP
>100,000 &>24"SP
Assembly
Drawings
Fabrication
Drawings
4 Wks.
4
4-6
6-8
8
8
Equip. Delivery
10-14 Wks.a
14-183
6-10
14-20
18-24
26
26
Equip. Erection
1 Wk.
2
Debugging
Testing
Special material or castings require additional time.
-------
wet scrubbers is about 18 weeks. The average for large wet
scrubbers is about 23 weeks. The average figures for fans
are about 19 weeks for small units and 23 weeks for large
high-pressure units.
Ancillary Equipment - Table 4.5 summarizes data obtained
from vendors for waste-water treatment equipment and ancillaries
for the air pollution control device.
4.1.2 Case Histories
Case-history data obtained from the vendors were compared
with present quoted times for fabrication and construction.
Because of the variability in quoted delivery times for
electrostatic precipitators, emphasis was placed on obtaining
information pertinent to precipitator installations.
In analysis of the case-history data, the highly variable
and time-consuming activities, such as those preceding the
award of contract and equipment tie-in, were separated from
the activities of reasonably consistent durations, such as
those from contract award to completion of construction.
Times were then compared with the corresponding figures
obtained from vendors for expected or projected schedules.
4-7
-------
Table 4.5 VENDOR DELIVERY SCHEDULES FOR ANCILLARY EQUIPMENT
I
00
Source
A
A
A
B
B
B
Equipment
Electric Motors
Electric Motors
Electric
Transformers
Electric
Transformers
Fans , High
Volume, High SP
Rotary Drum
Filter
Rotary Drum
Filter
Thickener
Thickener
Centrifuge
Size
Large
1000 to
2500 HP
Large
Special
1500
KVA-TX
Spec, or
Rubber
Lined
Carbon
Steel
Stainless
Steel
24' Dia.
75" Dia.
Bowl Type
Assembly
Drawings
4-5 Wks.
4-5
2-3
2-3
8
2
2
2
3
2
Drawings
Approval
2 Wks.
2
2
2
2
1
1
1
1
1
Delivery Time
15 Wks.
17
32
12-14
^•26
25-27
27-29
21-23
25-27
24
Erection
3 Wks.
3
2
3
2
-------
The case histories selected for evaluation are primarily
those of single unit installations. Data on multiple unit
installations were used after deducting the expected additional
time required to complete construction of the additional units.
Values for the period "contract award to completion of
construction" are plotted against electrostatic precipitator
capacity in Figure 4.1. This graph shows a steep rise in the
"contract award to completion of construction" time for small
capacities up to about 300,000 CFM. Beyond that capacity, the
rise is more gradual.
The average time from contract award to completion of
construction for electrostatic precipitators with capacities
lower than 300,000 CFM is 60 weeks. The average for units
with capacities higher than 300,000 CFM is 80 weeks.
For purposes of comparison, two sets of lines are super-
imposed on Figure 4. 1. One set, based on a summary of the
quoted vendors data with regard to the time required for
equipment fabrication and erection, shows 46 weeks for small
electrostatic precipitators and 58 weeks for large units.
The other sets of lines show the figures that were used to
prepare the compliance schedules reflecting expeditious
installation of electrostatic precipitators. These figures
4-9
-------
0)
X
w
w
N.
§ 120
o
H
EH
U
EH
o 100
u
o
o
H
EH
w 80
d
o
o
EH
Q 60
§
§
£_,
O
s
EH 40
O
U
s
§
rv,
I-M
w 20
H
EH
Q
Cfl
§
0 A
e
o
0 °
A
A X X X X X X K-a» X
0
A ©A. Q
— X— ic— T— X-
A O Source (A) Data
A A A Source (B) Data
Case Histories Averages
— X — Compliance Schedules Averages
— ._ Vendors Schedules Averages
0 200 400 600 800
(ELECTROSTATIC PRECIPITATOR), 1000 CFM
Figure 4.1 Case-history data
for electrostatic precipitators.
1000
4-10
-------
represent a compromise between the expected or projected
schedules furnished by the vendors and actual time requirements
found in the case histories, which were affected by contingencies
and unforeseen delays.
The points on the graph also indicate that fabrication and
construction of the electrostatic precipitators manufactured by
the larger of the two companies required somewhat more time
than the installations of the smaller company.
The limited case-history data obtained for installation of
other types of control devices agreed substantially with figures
cited by the vendors.
4.2 Industrial Contacts
Representatives from most of the industries studied were
contacted to substantiate the information prepared for each
industry with regard to operating practices, atmospheric
emissions, and types of high-efficiency controls most commonly
used and to ensure that control problems specific to that
industry were not overlooked. The compliance schedules relating
to installation of air pollution control devices for each type
of industry operation were discussed. The persons contacted
generally believe that the compliance schedules are reasonable
if they are considered as representing the most expeditious
cases.
4-11
-------
Contacts with industry also yielded information on the
practices of some companies in procuring control devices. Some
examples are given below in terms of type of control device.
These examples illustrate the inadequacy of case-history data
alone as a basis for compliance schedules, since some installations
are not performed in the most expeditious manner.
Wet Scrubbers - One large iron and steel manufacturer invites
selected vendors to study the air pollution problem and to offer
solutions based on use of their equipment. The sequence of
activities, which the steel manufacturer considers as time
required to obtain a proposal, is as follows:
Activity
1) Preliminary investigation, outline of
process and problem
2) Request for engineering proposal from
vendors including approach to problem
and delivery time on equipment, but
excluding price information
3) Review of proposal and approach to
problem
4) Final engineering proposal (excluding
price information)
5) Internal review and analysis
6) Meeting with bidders
7) Firm proposal preparation, including
price information
8) Award of contract
Duration
Several months
6-8 weeks
4 weeks
6-8 weeks
4 weeks
4 weeks
6-12 weeks
2-3 weeks
4-12
-------
In this instance, a high-energy wet scrubber was selected
to control particulate emissions from an open hearth furnace,
an electric arc furnace, and a sintering plant.
Analysis of this sequence in terms of the compliance
schedule for installation of large high-energy wet scrubbers
shows that Steps 1, 2, and 3 above correspond to activities
between A and G on the schedule. Step 4 is G-l, Steps 5, 6,
and 7 are activity 1 to J, and Step 8 is J-2.
A composite compliance schedule made up partly of the
above information, including delivery time of the controlling
equipment (in this case the high pressure/through-put fan) and
supplemented with reasonable times for the missing activities,
indicated a compliance period of about 76 weeks; this is in
line with the expeditious schedule prepared for large high
energy scrubbers. Figure 4.2 summarizes the installation
schedule.
Electrostatic Precipitator - A cement manufacturer supplied
his projected schedule for installation of a custom electro-
static precipitator (300,000 CFM) on a cement kiln. At the
time this information was presented, only Steps 1 and 2 were
completed.
4-13
-------
Figure 4.2 Schedule for installation of high
energy wet scrubber on steel furnace.
= Milestones
*• - Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agencyD
2 Date of award of control device contract.
3 Date of initiation of on-site construction or installation of emission control equipment.
4 Date by which on-site construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ELAPSED TIME (WEEKS)
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
Designation
K-L Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
Activity Duration
1) Preliminary layout and preparation
of bids specification 9 weeks
2) Procurement of control device bids 22 weeks
3) Review of bids and award of contract 9 weeks
4) Vendor prepare assembly drawings 13 weeks
5) Fabrication and delivery of first
components to site 40 weeks
6) Construction, including tie-in time 36 weeks0
7) Startup, debugging, and emissions ,
testing 14 weeks
The reason given for this delay was noncompliance of the
vendors with specifications. Twelve weeks of diligent
effort would be more reasonable.
Unusually long time for submission of assembly drawings
(showing dimensions and weights). Eight weeks is more
reasonable.
0 A shorter duration of 24 weeks should be sufficient for
expeditious schedules. Longer duration is due in part to
cold winter months.
j
Duration of eight weeks should be reasonable for start-
up, debugging, and emissions testing.
A reasonable compliance schedule for this installation,
including four weeks for finalization of plans, is shown in
Figure 4.3.
Fabric Filters - A schedule for installation of a custom-
designed 150,000 ACFM fabric filter on a large gray iron
cupola is given below; it includes the time required to modify
the charging mechanism to the two cupolas.
4-15
-------
Figure 4.3 Schedule for installation of electrostatic
precipitator on cement kiln.
= Milestones
*• = Activity and duration in weeks
MILESTONES
1 Date of submittal of final control plan to appropriate agencyB
2 Date of award of control device contract.
3 Date of initiation of on-sife construction or installation of emission control equipment.
4 Date by which on-«ite construction or installation of emission control equipment is completed.
5 Date by which final compliance is achieved.
ACTIVITIES
Designation
A-C
A-B
C-D
D-E
E-F
F-G
G-l
1-H
H-J
J-2
2-K
Preliminary investigation
Source tests
Evaluate control alternatives
Commit funds for total program
Prepare preliminary control plan and compliance
schedule for agency
Agency review and approval
Finalize plans and specifications
Procure control device bids
Evaluate control device bids
Award control device contract
Vendor prepares assembly drawings
IIP
Designation
K-l Review and approval of assembly drawings
L-M Vendor prepares fabrication drawings
M-N Fabricate control device
L-O Prepare engineering drawings
O-P Procure construction bids
P-Q Evaluate construction bids
Q-3 Award construction contract
3-N On-site construction
N-R Install control device
R-4 Complete construction (system tie-in)
4-5 Startup, shakedown, preliminary source test
-------
ACTIVITY DURATION
1) Award of engineering contract
2) Completion of engineering and
fabrication drawings 63 weeks
3) Delivery of first material to site 14 weeks
4) Completion of construction and
emission testing. 24 weeks
Long duration partly due to backlog of work by the
engineering company. Twenty-six weeks should be more
than adequate for completion of this phase of the project,
A reasonable compliance schedule, including four weeks
of finalization of plans, is shown in Figure 4.4.
4-17
-------
Figure 4.4 Schedule for installation of custom
designed fabric filter on gray iron cupola.
2.0
i
M
00
MILESTONES
1
2
3
4
5
ACTIVITIES
DESIGNATIONS
1 -2
2-3
3 -4
4 -5
ELAPSED TIME (WEEKS)
Dote of sobmittal of final control plan to appropriate agency.
Date of award of control device contract.
Date of initiation of on-site construction or installation of emission control equipment.
Date by which on-site construction of emission control equipment is completed.
Date by which final compliance is achieved .
Preparation of detailed engineering and fabrication drawings, equipment specifications,
construction bid documents and award of construction contract.
Equipment fabrication and delivery of structural components to site .
Delivery of remaining equipment and completion of construction including process tie in.
Equipment start up and source testing.
-------
BIBLIOGRAPHIC DATA
SHEET
1. Report No.
EPA-340/l-73-001-a
3. Recipient's Accession No.
4. Title and Subtitle
Technical guide for review and evaluation of compliance
schedules for air pollution sources
5- Report Date
August 1973
6.
7. Author(s)
PEDCo Environmental Specialists
8. Performing Organization Rept.
No.
41U-762-5
9. Performing Organization Name and Address
PEDCo Environmental Specialists
Suite 3, Atkinson Square
Cincinnati, Ohio 45246
10. Pro)ect/Task/Work Unit No.
11. Contract/Grant No.
68-02-0607, Task 5
12. Sponsoring Organization Name and Address
Environmental Protection Agency
Division of Stationary Source Enforcement
Research Triangle Park, N. C. 27711
13. Type of Report & Period
Covered
Task Report - Final
14.
15. Supplementary Notes
Prepared under subcontract to:
Research Triangle Institute
P.O. Box 12194. Research TrianglP Parlc, N.C. ?77pq
16. Abstracts
Estimates are given of time periods which are as expeditious as practicable
for applying reasonably available control technology, including process modifications
as well as add-on control devices or equipment, to various air pollution source
categories. Process descriptions are given for the sources. These model compliance
schedules indicate time periods required for completing increments of progress and
achieving milestones as required by 40 CFR 51.15. Schedules are given for 34
industries in the following source categories: stationary combustion, solid waste
disposal, evaporation sources, chemical processes, agricultural products, primary
metallurgical processes, secondary metallurgical processes, mineral industries,
petroleum industry, pulp and paper.
17. Key Words and Document Analysis. 17o. Descriptors
Air Pollution Control Equipment
Airborne Wastes
Regulations
Schedules
Lead Time
17b. Identifiers/Open-Ended Terms
Schedules, for compliance with air pollution regulations
40 CFR 51.15
17c. COSATI Field/Group
18. Availability Statement
Unlimited
19. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNCLASSIFIED
21. No. of Pages
276
22. Price
FORM NTIS-35 (REV. 3-72)
USCOMM-DC 14952-P72
5-1
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